Millstar 2007 Interactive Catalog

Transcription

New for 2007 Tooling Shown in Green
PROFILE MILLING TOOLS
STEEL SHANK TOOL HOLDERS
COPY MILLING & PROFILING INSERTS
MB, MBT, RB-N, VRBS, BS-N
BACK DRAFT, FLAT BOTTOM & TOROID INSERTS
BDS, BD-R, VBD, TO, BD-N
HF HIGH FEED SERIES INSERTS
TOBD-NF FOR ALUMINUM
LONG REACH SOLID CARBIDE SHANKS
SHRINK FIT
TOROID "BUTTON" CUTTER
ULTRA PRECISION END MILLS
ENDMILL EXPANSION
3
4
5
6
7
8
8
9
10
11
12-13
14-15
COPY MILLING & PROFILING INSERTS
MB, MBT, RB-N, VRBS, BS-N
BACK DRAFT, FLAT BOTTOM & TOROID INSERTS
BDS, BD-R, VBD, TO, BD-N
HF HIGH FEED SERIES INSERTS
TOBD-NF FOR ALUMINUM
LONG REACH SOLID CARBIDE SHANKS
SHRINK FIT
TOROID "BUTTON" CUTTER
ULTRA PRECISION END MILLS
16
17
20
20
21
22
23
24-25
ENDMILL EXPANSION
26-27
DESIGN, COATINGS, FEED & SPEED
GENERAL FEED & SPEED RECOMMENDATIONS
FEED & SPEED CALCULATIONS
28
29-30
31
18
19
Cost cutting and time saving tools for profile and
cavity milling in the auto, aircraft, die and mold
industries, and in general manufacturing.
Millstar tools are designed for conventional profile
machining, and for high speed and hard milling with
modern machine tools and methods. Tool holders and
inserts are available in inch and metric sizes. This issue of
the Millstar catalog also features special and new inserts. A
series of aggressively positive inserts for cutting aluminum
and non-ferrous materials, a Toroid bull nose series and a
new MBT SuperFinisher series.
• Insert Style Ball Nose Roughing and Finishing Tools
• Flat Bottom, Back Draft and Toroid Bull Nose Tools
• SuperFinisher Inserts
• New Long Reach Solid Carbide Shanks
• New Shrink Fit Shank System
• New High-Feed Inserts and Solid Carbide Tools
• Special High Shear Aluminum Geometry
Millstar Profile Milling Tools represent the latest in profile
and contour milling technology, providing you with the
competitive edge of shorter machining and lead times, and
the competitive advantages of higher machining accuracy
and true contouring results.
Better surface finishes = Reduced finishing work
Run and feed faster = Reduced machining time
Increased tool life = Reduced tool changes and cost
Mill with accuracy & consistency = Reduced manual rework
Two-flute efficient, balanced milling action = Greatly
increased metal removal productivity
The Tool Holders
Millstar is proud to offer the largest selection of roughing and
finishing ball nose, back draft, flat bottom and toroid milling
cutters available from one source. Cylindrical and tapered
toolholders (to 15 inch length) include the longest reach
profiling tools available as standard catalog items. Tool
holders are inherently balanced for high spindle speeds.
Machine with confidence at the increased speeds and
velocities dictated by modern high velocity machining. Super
intelligent machine controls with high speed data transfer,
rapid advances in cutting edge materials and coating
technologies enable ever faster machining speeds and
increased productivity. Millstar tools are designed to keep pace.
The Millstar product line is manufactured in the USA under
ISO 9001 specifications, and all tools are fully traceable.
Nearly six decades of cutting tool design and manufacturing
for automotive, aerospace and many other industries, as well
as special design capabilities using 3-D CAD allow us
to respond quickly to requests for special designs.
The Inserts
• Millstar inserts are fully ground precision inserts for better
chip control, faster metal removal and higher surface
accuracies. They are far more accurate than pressed and
O.D. sharpened inserts. Millstar insert radius and seat are
accurate to +/- 0.00025" (+/- 0.0065 mm) of nominal radius
and cut exactly as programmed. This unparalleled accuracy
also eliminates redundant Z-axis pick ups and assures
accurate blending.
• Positive ground chipbreaker or strong negative
cutting edge designs guarantee outstanding
cutting performance in a wide variety of ferrous
and non-ferrous materials.
• A choice of state-of-the-art insert grades,
designs and tool coatings allow for optimum
speed and feed rates in wet and dry
machining. Reduced machining times by
25% to 60% are not uncommon.
• Economical one-piece inserts with two
cutting edges are cost-effective for contour
milling. True radius geometry is fully CNCground for higher machining accuracy and
greatly reduced manual finishing and
polishing time.
• Choose from side-cutting ball nose inserts with 180 degree
nose radius, and popular ball nose inserts with a cutting
edge covering 230 degrees for steep wall up-and-down
ramping, profiling, contour milling and blending,
and for a wider range of applications compared to
conventional ball nose tools.
• Select from a variety of flat bottom, back draft and toroid
inserts for steep or straight wall milling with long extensions
on hard to reach cores, cavities or fillets. Milling with
small radii prevents deflection and results in superior
finishes and contour accuracies. Available with or
without chipbreaker and coating in a variety of corner
radii and sizes.
Rock Solid Insert Clamping
Cutting insert clamping is highly accurate and rigid.
Unique V-pocket design gives a truly positive seat for
the insert and will not allow insert movement when
milling with a side thrust. “Sandwiched” insert clamping
with single locking screw is unsurpassed for rigidity.
The advanced design of Millstar inserts eliminates
heat-seizing of locking screws or insert movement due
to costly locating screws or pins of less advanced
design. Positive V-pocket seating eliminates mismatch
when changing to fresh inserts. It also eliminates the
need to program new length or diameter offsets.
3
D2
STYLE CY/SFCY
D
D1
Shank Ø
D1
1/2
1/2
3/8
1/2
1/2
1/2
1/2
1/2
12mm
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
1
1
1
25mm
1
1
25mm
1 1/4
1 1/4
1 1/4
1 1/4
1 1/4
1 1/2
1 1/2
L2
Neck Ø Neck Length Total Length
D2
L1
L2
.225
1 1/4
3 3/4
.281
1 1/4
3 3/4
.337
3/4
4
.337
1
4
.337
1 3/4
6
.440
1 1/4
4
.440
1 1/2
5
.440
1 3/4
6
.440
1 3/4
6
.440
2
7 1/2
.550
1 3/8
5
.550
2
6 1/4
.550
2 1/4
7 1/2
.675
1 3/4
4 1/2
.675
2
6
.675
2 3/8
7 1/2
.675
2 3/8
9
.675
3 1/2
8
.675
3 1/2
10
.882
1 3/4
6
.882
1 3/4
6
.882
2 1/2
8
.882
2 3/4
10
.882
2 3/4
10
.882
4
10
.882
4
12 1/2
.882
4
15
1.125
2 1/4
7 1/2
1.125
3
10
1.125
4
9
1.125
4
12
For your shrink fit and long reach requirements please see pages 9,10, 21 & 22 for our carbide shank products.
4
D1
L1
L2
Size Ø
D
1/4
5/16
3/8
3/8
3/8
1/2
1/2
1/2
1/2
1/2
5/8
5/8
5/8
3/4
3/4
3/4
3/4
3/4
3/4
1
1
1
1
1
1
1
1
1 1/4
1 1/4
1 1/4
1 1/4
.
6
D
L1
Tool
Ordering No.
TAV 0250-3.75-0500
TAV 0312-3.75-0500
CY 0375-4.0-0375
CY 0375-4.0-0500
TA 0375-6.0-0500
SFCY 0500-4.0-0500
SFCY 0500-5.0-0500
SFCY 0500-6.0-0500
SFCY 0500-6.0-12 NEW
SFTA 0500-7.5-0625
SFCY 0625-5.0-0625
SFCY 0625-6.25-0625
SFTA 0625-7.5-0750
SFCY 0750-4.5-0750
SFCY 0750-6.0-0750
SFCY 0750-7.5-0750
SFCY 0750-9.0-0750
SFTA 0750-8.0-1000
SFTA 0750-10.0-1000
SFCY 1000-6.0-1000
SFCY 1000-6.0-25 NEW
SFCY 1000-8.0-1000
SFCY 1000-10.0-1000
SFCY 1000-10.0-25 NEW
SFTA 1000-10.0-1250
SFTA 1000-12.5-1250
SFTA 1000-15.0-1250
SFCY 1250-7.5-1250
SFCY 1250-10.0-1250
SFTA 1250-9.0-1500
SFTA 1250-12.0-1500
D2
STYLE TA/SFTA
Use with
Insert Style
Insert
Screw
MS 06N
MS 08N
MS 10
MS 10
MS 10
MS 12
MS 12
MS 12
MS 12
MS 12
MS 16
MS 16
MS 16
MS 20
MS 20
MS 20
MS 20
MS 20
MS 20
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 32
MS 32
MS 32
MS 32
Insert
Torx Key
T7
T7
T15
T15
T15
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T30
T30
T30
T30
NEW!
MBT
Precision ground, harder grade,
for semi-finish and finish milling. Excellent
choice for unattended finish milling at small
depth and high speeds and feed rates.
SuperFinisher
Ball Nose Insert
D
L
Part No.
MBT 0375
MBT 0500
MBT 0625
MBT 0750
MBT 1000
MBT 1250
D
.375
.500
.625
.750
1.000
1.250
Used for rough- to finish-milling small radius
or detail work, and surface milling in soft
and hard steel, cast iron, aerospace and
non-ferrous alloys, graphite, etc. Suitable for
high speed and hard milling.
VRBS
Small Ball Nose
Insert
L
.349
.377
433
.518
.716
.865
D
Part No.
VRBS-0250
VRBS-0312
D
L
.250
Unique cutting edge allows performance in all
operations in material below 42 HRc; in semi,
& finishing operations above. Significant
benefits in heat-treated intricate geometries.
Insert geometry allows smoother cutting
motion-diminishing heat build up & tool
deflection, reduces vibration caused by
cutting action.
Ball Nose Insert
D
L
Part No.
MB 0375
MB 0500
MB 0625
MB 0750
MB 1000
MB 1250
D
.375
.500
.625
.750
1.000
1.250
L
.294
.184
These strong precision inserts are
cost-effective replacements for
solid carbide ball end mills.
2˚
MB
D
.250
.312
For additional tool holders, see
page 6.
.312
RB-N
Precision ground, non-chipbreaker.
Best choice for cavity, core and profile
milling of pre-hard and fully hard die/mold
steels, cast steels and cast iron. Strongest
cutting edge design.
Ball Nose Insert
D
L
.349
.377
.443
.518
.716
.865
L
BS-N
Ball Nose Insert
D
S
Part No.
RB 0375 N
RB 0500 N
RB 0625 N
RB 0750 N
RB 1000 N
RB 1250 N
D
.375
.500
.625
.750
1.000
1.250
L
.390
.377
.443
.518
.716
.865
Sidecutting, non-chipbreaker. Side cutting
insert used in cavity and core profiling, for
blending of fillets on medium and hard
materials.
Part No.
BS 0375 N
BS 0500 N
BS 0625 N
L BS 0750 N
BS 1000 N
BS 1250 N
D
.375
.500
.625
.750
1.000
1.250
L
.390
.350
.421
.496
.679
.828
S
.154
.100
.109
.121
.179
.203
5
D2
STYLE CYF
D
D1
D1
L1
L2
Size Ø
D
1/4
5/16
3/8
3/8
3/8
3/8
3/8
1/2
1/2
1/2
1/2
5/8
5/8
3/4
3/4
3/4
1
1
1
1
1
1
1
1
1 1/4
1 1/4
1 1/4
1 1/4
L2
Shank Ø
D1
1/2
1/2
3/8
3/8
1/2
1/2
1/2
1/2
1/2
12mm
5/8
5/8
3/4
3/4
3/4
1
1
25mm
1
1
25mm
1 1/4
1 1/4
1 1/4
1 1/4
1 1/4
1 1/2
1 1/2
D2
L1
L2
.225
1 1/4
3 3/4
.281
1 1/4
3 3/4
.337
3/4
4
.337
3/4
4
.337
1
4
.337
1 3/4
6
.337
1 3/4
6
.440
1 1/4
4
.440
1 3/4
6
.440
1 3/4
6
.440
2
7 1/2
.550
2
6 1/4
.550
2 1/4
7 1/2
.675
2
6
.675
2 3/8
9
.675
3 1/2
10
.882
1 3/4
6
.882
1 3/4
6
.882
2 1/2
8
.882
2 3/4
10
.882
2 3/4
10
.882
4
10
.882
4
12 1/2
.882
4
15
1.125
2 1/4
7 1/2
1.125
3
10
1.125
4
9
1.125
4
12
6
.
6
D
L1
Tool
Ordering No.
TAV 0250-3.75-0500
TAV 0312-3.75-0500
CYF 0375-4.0-0375
CY 0375-4.0-0375
CY 0375-4.0-0500
TA 0375-6.0-0500
TAF 0375-6.0-0500
CYF 0500-4.0-0500
CYF 0500-6.0-0500
CYF 0500-6.0-12 NEW
TAF 0500-7.5-0625
CYF 0625-6.25-0625
TAF 0625-7.5-0750
CYF 0750-6.0-0750
CYF 0750-9.0-0750
TAF 0750-10.0-1000
CYF 1000-6.0-1000
CYF 1000-6.0-25 NEW
CYF 1000-8.0-1000
CYF 1000-10.0-1000
CYF 1000-10.0-25 NEW
TAF 1000-10.0-1250
TAF 1000-12.5-1250
TAF 1000-15.0-1250
CYF 1250-7.5-1250
CYF 1250-10.0-1250
TAF 1250-9.0-1500
TAF 1250-12.0-1500
D2
STYLE TAF
Use with
Insert Style
Insert
Screw
MS 06N
MS 08N
MS 10
MS 10
MS 10
MS 10
MS 10
MS 12
MS 12
MS 12
MS 12
MS 16
MS 16
MS 20
MS 20
MS 20
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 32
MS 32
MS 32
MS 32
Insert
Torx Key
T7
T7
T15
T15
T15
T15
T15
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T30
T30
T30
T30
Back Draft and Flat Bottom
inserts are used to best advantage
in applications where small corner
radii are required, for example
finishing of straight and steep side walls,
blending and finishing of small corner radii,
fillets and the like. Toroid Bull Nose Cutters
combine the advantages of popular round insert
toroidal “button cutters” and bull nose end mills
with the proven design of Millstar’s precision, single
strong insert with twin-cutting geometry. The result is
reduced machining time and enhanced accuracy and
surface finish.
{
The inserts, and particularly the patented toroidal inserts, are designed
to improve 3- and 5-axis milling of dies, molds and similar free-form
three-dimensional surfaces. The precision ground inserts are held in
Millstar’s proven rock-solid dovetail seat for superior surface finish and
machining accuracy. The insert designs avoid the area of zero cutting
speed at the tip of ball nose inserts for improved tool life.
The toroidal tools in particular have the advantage of cutting at larger
step-over or pitch while leaving no or smaller cusps; the tools also run
at faster cutting speeds and feed rates. The toroidal bull nose design
simplifies 3- and 5-axis programming, works on a variety of materials from
non-ferrous metal, carbon graphite and stainless steels to pre-hard and
fully hard mold and die materials.
VBD
Used for rough-to finish-milling small radius
or detail work, and surface milling in soft and
hard steel, cast iron, aerospace and non-ferrous
alloys, aluminum alloys, graphite, etc. Suitable
for high speed and hard milling.
Small Back Draft
Insert
D
Part No.
VBD-0250
VBD-0312
R
L
D
.250
.312
L
.313
.215
R
.015
.015
These strong precision inserts are costeffective replacements for solid carbide
end mills.
1˚
For additional tool holders, see page 4.
TO
Precision ground, large corner radius & back
taper for spiral and pocket milling, milling of
pre-hard and hardened flat surfaces at higher
speeds than tools with smaller corner radii.
Good choice for HS milling of Aluminum.
Toroid Bull Nose
Insert
D
R
L
Part No.
TO 0375
TO 0500
TO 0625
TO 0750
TO 1000
TO 1250
D
.375
.500
.625
.750
1.00
1.25
L
.349
.377
.433
.518
.716
.865
R
.125
.125
.156
.187
.250
.312
Mill faster, more accurate than “two
button” round insert cutters.
NEW!
BDS
Unique crossover design between flat
Flat Bottom Insert bottom FB and back draft BD inserts. Allows
straight walls with a larger step down than
BD, but less cutting forces than FB; allows
higher cutting speeds and feeds.
Part No.
BDS-0375BDS-0500BDS-0625BDS-0750BDS-1000-
R
L1
BD-R
Back Draft Insert
D
R
L
D
.375
.500
.625
.750
1.000
1.250
L
.340
.380
.457
.540
.740
.919
R
1/32
1/32 / 1/16 / 1/8
1/32 / 1/16
1/32 / 1/16 / 1/8
1/32 / 1/16 / 1/8
1/32 / 1/16 / 1/8
Precision ground, non-chipbreaker and 7
degree backtaper. Used for milling of
cores, cavities, fillets with straight or very
steep walls of harder material.
Back Draft Insert
D
D
L1
R
.375
0.125
1/32
.500
0.125
1/32 or 1/16
.625
0.125
1/32 or 1/16
.750
0.125
1/32 or 1/16
1.000
0.125
1/32 or 1/16
All “BDS” series inserts are non-chip
breaker style**
Precision ground, with positive ground
chipbreaker and 7 degree back-taper. Used
for milling of cores, cavities, fillets with
straight or very steep walls
of softer material.
Part No.
BD 0375 R
BD 0500 R
BD 0625 R
BD 0750 R
BD 1000 R
BD 1250 R
BD-N
R
L
Part No.
BD 0375 N
BD 0500 N
BD 0625 N
BD 0750 N
BD 1000 N
BD 1250 N
D
.375
.500
.625
.750
1.000
1.250
L
.357
.380
.457
.540
.740
.919
R
1/32 / 1/16
1/32 / 1/16 / 1/8
1/32 / 1/16 / 5/32
1/32 / 1/16 / 1/8
1/32 / 1/16 / 1/8
1/32 / 1/16 / 1/8
FB-R
chipbreaker. Flat bottom insert for shoulder
Flat Bottom Insert milling, fillet finishing and long reach
angular wall finishing of softer materials.
D
Part No.
FB
0250 R
R
FB 0312 R
FB 0375 R
L FB 0500 R
FB 0625 R
FB 0750 R
FB 1000 R
FB 1250 R
D
.250
.3125
.375
.500
.625
.750
1.000
1.250
L
.270
.270
.341
.350
.421
.496
.679
.843
R
.015
.015
1/32
1/32 / 1/16 / 1/8
1/32 / 1/16
1/32 / 1/16 / 1/8
1/32 / 1/16 / 1/8
1/32 /1/16 / 1/8
7
NEW!
New HF (High Feed) Inserts
Millstar’s new HF insert is designed for High Speed and High Feed
machining. The HF is designed to run at high cutting speeds and feed rates
with shallow depth of cut. The NEW curved geometry allows
the chip to flow up and out of the cut quickly and
smoothly allowing for the use of heavy chip loads.
The geometry of the new HF insert generates cutting
forces upward, toward the spindle, which helps
eliminate vibration and deflection, allowing for very
Tool
Diameter
Ordering No.
D
HF-0375…
HF-0500…
HF-0625…
HF-0750…
HF-1000…
0.375
0.500
0.625
0.750
1.000
high chip loads. The HF insert is designed to fit into Millstar’s
standard flat holders, style 4 (CYF, TAF and CBCYF) making these holders
more versatile than ever.
The HF insert can be used in the following applications: Roughing, semifinish of all softer materials. Nickel-based alloys and Stainless steel alloys
(XRN coated) to pre-heat treated Tool steels (TLN coated). It can be used
for roughing and semi-finishing of heat-treated materials up to 48 HRc.
Corner Radius
A
Corner Radius
B
Length
D1
Step Over
Ae
Depth of Cut
Ap
Feed per Tooth
Fz
0.0155
0.0315
0.0470
0.0625
0.0755
0.1180
0.1575
0.1970
0.2360
0.2755
0.0125
0.0203
0.0235
0.0315
0.0345
0.28
0.375
0.46
0.56
0.75
0.016
0.019
0.025
0.030
0.039
.010-.020
.012-.022
.016-.028
.020-.035
.022-.040
.. After the part number please indicate TLN, XRN or HSN when ordering.
NEW!
New TOBD-NF Back Draft Inserts for
Non-Ferrous Materials
Millstar’s new TOBD-NF insert is specifically designed
for high speed and high feed roughing of Aluminum,
but also has the versatility to be used for fine
finishing as well. This unique cutting edge design
allows the chips to flow freely up the flute allowing higher speeds and
feeds. The TOBD-NF comes in diameters from 1/2 inch (12mm) up to 1 inch
(25mm) and fits into our standard flat type tool holders making the holders
Tool Ordering No.
Diameter
D
L
R
TOBD-0500-NF-NA
TOBD-0625-NF-NA
TOBD-0750-NF-NA
TOBD-1000-NF-NA
0.500
0.625
0.750
1.000
0.377
0.433
0.518
0.716
0.125
0.125
0.125
0.125
DISCLAIMER
Today’s metalcutting operations are performed on high horsepower, high spindle speed CNC machines. These operations generate high temperatures, cutting forces and flying
chips. Today’s metalcutting tools can generally hold up under these conditions but they may also chip and fly apart. Adequate protection for workers is a must. All machine
guards and protective equipment should be in place at all times. Grinding carbide, ceramic and other modern materials can create dusts and mists that should be collected by
proper equipment.
Overexposure to dusts and mists can be a hazard to ones health. Dusts and mists can irritate existing skin and or pulmonary conditions. Adequate respiratory, eye protection
and ventilation should be used during grinding and workers should avoid prolonged contact with dusts and mists.
A safe environment must be provided as metalcutting is not just the holder and inserts. The machine, workpiece, clamping method cutting conditions all play a part in today's
metal cutting environment.
Cole Tooling does not assume responsibility and will expressly disclaim liability for loss, damage or expense arising out of or in any way connected with the handling, storage,
use or disposal of these products. Cole Tooling does not warrant it’s products for any particular use or application. All information and recommendations in our catalogs are
only suggestions. All generally accepted safety practices and health regulations should be followed.
8
D2
D
D1
L1
L2
Millstar’s long solid carbide tool shank cutters provide the user with deep milling
solutions for up to ten times diameter in reach. MILLSTAR’s Carbide Tool Shanks
provide many user benefits:
• Increased stiffness – for more aggressive metal removal and long reach, deep milling.
• Large cutting insert choice – the variety of available cutting geometry, tool coatings, and
insert shapes and sizes assures best milling results at lowest machining cost per part.
• Minimized deflection – to machine closer to net shape and tight tolerance.
• Vibration reducing – for smoother surface finish, improved tool life,
longer spindle life.
• Minimized cutter run out – improved milling results in soft to fully hardened
(to 65 HRc) materials.
• Smaller shank to cutter diameter – several sizes have full-length side
clearance to machine straight walls.
• Safe high speed milling – highest tool stiffness and least deflection
when compared with steel and heavy metal tool shanks result in
process reliability and highest safety for operator and machine.
• Shank diameters (h6) – all tool shanks are heat shrink-fit tool
adapter compatible.
Tool
Ordering No.
Size Ø
D
CBTAV 0250-6.0-0500*
CBTAV 0250-6.0-0500 LT*
CBTAV 0312-6.0-0500*
CBTA 0375-6.0-0500
CBSFCY 0500-6.0-0500
CBCYF 0500-6.0-0500
CBSFCY 0500-6.0-12**
CBCYF 0500-6.0-12**
CBSFCY 0625-6.0-0625
CBCYF 0625-6.0-0625
CBSFCY 0750-8.0-18 **
CBCYF 0750-8.0-18 **
CBSFCY 0750-8.0-0750
CBCYF 0750-8.0-0750
CBSFCY 1000-8.0-1000
CBCYF 1000-8.0-1000
CBSFCY 1000-8.0-25**
CBCYF 1000-8.0-25**
.250"
.250"
.312"
.375"
.500"
.500"
.500"
.500"
.625"
.625"
.750"
.750"
.750"
.750"
1.000"
1.000"
1.000"
1.000"
Insert
Style
*-.250" and .312" diameter holders use new insert style
Overall
Length L2
Neck Length
L1
Shank Ø
D1 (h6)
Neck D2
inch
Nose
Taper
Screw/
wrench
6.125
6.125
6.125
6.125
6.625
6.625
6.625
6.625
6.750
6.750
8.875
8.875
8.875
8.875
9.125
9.125
9.125
9.125
1.181 taper
2.750 taper
1.181 taper
1.181 taper
1.145
1.145
1.145
1.145
1.325
1.325
1.5
1.5
1.512
1.512
1.866
1.866
1.866
1.866
.500
.500
.500
.500
.500
.500
12mm
12mm
.625
.625
18mm
18mm
.750
.750
1.00
1.00
25mm
25mm
.224
.224
.285
.337
.440
.440
.440
.440
.550
.550
17.95mm
17.95mm
.675
.675
.882
.882
.882
.882
6˚ (3˚/side)
6˚ (3˚/side)
6˚ (3˚/side)
6˚ (3˚/side)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
MS 06N / T7
MS 06N / T7
MS 08N / T7
MS 10 / T15
MS 12 / T20
MS 12 / T20
MS 12 / T20
MS 12 / T20
MS 16 / T20
MS 16 / T20
MS 20 / T20
MS 20 / T20
MS 20 / T20
MS 20 / T20
MS 25 / T20
MS 25 / T20
MS 25 / T20
MS 25 / T20
. Part number VRBS and VBD, page 5 & 7.
**-Tools with smaller shank diameter than cutter diameter for full-length side clearance.
9
Shrink Fit heads are interchangeable between inch and metric. For metric refer to page 22.
NEW!
Shrink Fit System
rigidity and the shrink tolerances offer better accuracy than
screw on type systems. These tools are designed for high speed machining
and hard metal machining and will allow for better tool life as well as better
surface finishes.
Millstar’s Shrink System offers versatility, strength and accuracy. The carbide
shanks and heads are interchangeable between inch and metric versions.
Metric heads fit on inch shanks and inch heads fit on metric shanks. The
12mm and 1/2 inch shanks will accept any head that is the same diameter
or smaller (see chart for connectivity). The carbide shank offers strength and
All diameters are available in short and long length versions.
Shanks for Shrink Fit Heads
Shrink Fit Heads
Tool
Ordering No.
Shank Ø
D1
Length
L1
Length
L2
Tool
Ordering No.
D1
Length
L1
Length
L2
CSS-0500-2.9-T1
CSS-0500-4.9-T1
CSS-0625-4.1-T2
CSS-0625-7.1-T2
CSS-0750-3.8-T3
CSS-0750-6.8-T3
.5000
.5000
.6250
.6250
.7500
.7500
2.900
4.900
4.100
7.100
3.800
6.800
.600
.600
.650
.650
.700
.700
CHTAV-0250-T1
CHTAV-0312-T1
CHTA-0375-T1
CHY-0500-T1
CHY-0625-T2
CHY-0750-T3
CHF-0500-T1
CHF-0625-T2
CHF-0750-T3
.460
.460
.460
.460
.550
.675
.460
.550
.675
1.700
1.700
1.700
1.700
1.500
1.900
1.700
1.500
1.900
.879
.827
.845
.857
L1
Use With
Insert Style
.857
L1
L1
L2
T1
D1
CHTA-0375-T1
T1
L2
CSS-0500-2.900-T1 / CSS-0500-4.900-T1
Used with Shrink Fit Heads:
CHTAV-0250-T1
CHTAV-0312-T1
6˚
.314
D1
6˚
.302
L2
CHTAV-0250-T1
D1
T1
D1
CHTAV-0312-T1
L1
L1
CHY-0500-T1
CHF-0500-T1
T1
6˚
.411
T1
L2
D1
.435
L2
CHTA-0375-T1
L1
L1
L2
T2
D1
T2
.550
CSS-0625-4.124-T2 / CSS-0625-7.124-T2
CHY-0625-T2 / CHF-06250T2
CHF-0625-T2
CHY-0625-T2
L1
L1
L2
D1
T3
T3
.675
CSS-0750-3.800-T3 / CSS-0750-6.800-T3
CHF-0750-T3
CHY-0750-T3
10
CHY-0750-T3 / CHF-0750-T3
CHY-0500-T1
CHF-0500-T1
High Performance Milling from Heavy Roughing
to Fine Finishing.
Millstar face mills are equally useful on newer high velocity machines and older slower
equipment and will optimize milling performance of all your machine tools. The hardened tool
bodies can be run at aggressive spindle speed and feed rates, when used with Millstar’s precision
ground, strong and thick, round inserts with proven hard, high performance TLN tool coating.
The tools provide for precision finish results, minimal tool deflection and run-out. Excellent milling
results can be achieved in roughing, semi finishing and fine finishing in Z-level, profiling or raster
cuts, as well as in linear or circular interpolation milling or ramping.
The tools may be used with coolant, but we recommend dry, mist or MQL
(minimum quantity lubrication) milling with strong air blast when high speed or
hard machining steel, particularly in the higher hardness range
(> 45HRc / 425 HBN). Please refer to FAQs (frequently asked questions) about
milling on our website www.millstar.com.
Insert Style
.393"/10mm
.472"/12mm
.629/16mm
.125
.156
.205
Coating
.153
.154
.1875
TLN
TLN
TLN
S3
d1
FMI-1003
FMI-12T3
FMI-1604
Diameter Thickness Diameter
d
S
d1
S1
15˚
Tool
Ordering No.
d
S
S2
L2
Arbor Style
Key Slot
Cutting
Neck
No. Overall
Tool
Diameter Diameter
of
Length
Ordering No.
D
D1
Flutes
L2
Insert
Required
Insert
Screw
S1
Face
Clamp Mounting
Bore
Screw
Screw Diameter Drive
S2
S3
D2
Key
FMA 2000/5
FMA 2500/5
FMA 3000/5
FMI-12T3
FMI-12T3
FMI-12T3
FMIS-1
FMIS-1
FMIS-1
FMIS-2
FMIS-2
FMIS-2
2.0
2.5
3.0
1.57
1.57
1.57
5
5
5
STYLE 1
2.0
2.0
2.0
S2
L2
.75
1.0
1.0
STYLE 2
D
L2
S2
L1
D
D2
D2
D1
D2
.312
.375
.375
S1
L1
D1
FMIS-4
FMIS-4
FMIS-4
D1
S1
D
Shank Style
Tool
Ordering No.
FM-1000/2-6.0-1000
FM-1250/3-6.0-1000
FM-1500/4-6.0-1250
Cutting Ø Shank Ø
D
D1
1.00
1.25
1.50
1.00
1.00
1.25
Neck Ø
D2
No. of
Flutes
Neck Length
L1
Shank
Style
OAL
L2
Insert
Insert Screw Face Clamp Screw
Required
S1
S2
.882
.882
1.125
2
3
4
3.0
1.5
1.5
1
2
2
6.0
6.0
6.0
FMI-12T3
FMI-12T3
FMI-12T3
FMIS-1
FMIS-1
FMIS-1
FMIS-2
FMIS-2
FMIS-2
11
Hi-Tech Tools for
Hi-Tech Applications
in Your Industry
Millstar’s Hi-Tech Cutting Tools are ideal
choices for accurately and aggressively
machining products in many industries. Here
are some examples
• Mold and die making: injection molds, glass
molds, forging dies, extrusion dies.
• Aerospace: engine, landing gear and tail
hook components, structural components,
blisks, airfoil machining and forging dies,
helicopter rotor components.
• Power generating: turbine blades and other
components.
• Medical: hip and knee replacement joints,
surgical instruments, medical device molds.
• Automotive: stamping dies, wheel and tire
molds, ball joints, cam shaft machining,
racing engine details, bumper and other
injection molds, die cast dies, forging dies
for crank and cam shafts, connecting rods,
steering knuckles and yokes, and many other
forged components.
• Consumer products: molds for cake forms
and baking dishes, cell phones, lawn chairs,
trash cans, toys, bottles, recyclable cutlery
and dishes, jewelry, golf clubs, safety
helmets, computer and accessory housings
and much more.
Call on Millstar application specialists or visit
our web site www.millstar.com for more
product information and expert
application assistance.
12
Millstar’s new High Performance and ultra-precise solid carbide end mills were specifically
designed for High Speed, High Velocity and Hard Steel milling. Designed with specially selected
premium sub-micron carbide substrate, special tool geometry and proprietary heat-defying EXALON
tool coating, these tools are beating the best products the competition has to offer. They are made
in the United States, and are competitively priced. Please note just some of the benefits to users:
• Square nose tools Series EMS / EIS with sharp corner or square nose tools Series EIB / EMB with
corner radius, all with medium-high helix and strong cutting edges and tool body, work
extremely well in materials up to 65HRc as well as in softer materials.
• Ball nose tools Series BI / BM are designed with two flutes and special nose geometry for true
High Speed and Hard Material milling up to 68 HRc. Ball nose tools are the most aggressive tools
for these applications. We will be glad to share our proven approach to improving your
machining results.
• A new Toroid Series TOI / TOM with large corner radius and slight back taper is a Millstar
innovative addition. It is very useful in I.D. and O.D. Z-level and spiral milling at constant tool
pressure, pocket milling, and milling of pre-hard and hardened flat surfaces at higher speeds than
tools with smaller or sharp corner radii.
• Extended Reach ball nose tools Series BMNL and extended reach square nose tools Series EMR
are useful tools specifically designed for long reach milling of extrusion dies, deep cavities and
cores, deep rib milling and similar applications. The reduced flute length and
neck diameter assure constant cutting pressure and
minimal tool deflection.
End Mills, Square End, Series EIS
Exalon (AlTiN)-Coated
Tool
Ordering No.
EIS-.020-EX
EIS-.031-EX
EIS-.062-EX
EIS-.093-EX
EIS-.125-EX
EIS-.187-EX
EIS-.250-EX
EIS-.312-EX
EIS-.375-EX
EIS-.437-EX
EIS-.500-EX
Cutter Diameter
tol. +0 /–.0004
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
0.020
.031 / (1/32)
.062 / (1/16)
.093 / (3/32)
.125 / (1/8)
.187 / (3/16)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
–
–
–
–
–
–
–
–
–
–
–
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
3
3
4
4
5
6
6
6
6
6
6
0.020
0.031
0.062
0.093
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.060
0.100
0.200
0.300
0.375
0.600
0.750
1.000
1.125
1.315
1.500
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
2.5
2.5
2.5
2.5
3
3
3
3.5
3.5
4
4
Cutter Diameter
tol. +0 /–.0004
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
.062 / (1/16)
.093 / (3/32)
.125 / (1/8)
.125 / (1/8)
.187 / (3/16)
.250 / (1/4)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
0.015
0.015
0.015
0.030
0.030
0.015
0.030
0.030
0.030
0.030
0.030
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
4
4
5
5
6
6
6
6
6
6
6
0.062
0.093
0.125
0.125
0.187
0.250
0.250
0.312
0.375
0.437
0.500
0.200
0.300
0.375
0.375
0.600
0.750
0.750
1.000
1.125
1.315
1.500
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
–
2.5
2.5
3
3
3
3
3
3.5
3.5
4
4
Cutter Diameter
tol. +0 /–.0004
Ball
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
0.020
.031 / (1/32)
.062 / (1/16)
.090
.093 / (3/32)
.125 / (1/8)
.187 / (3/16)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
0.01
0.015
0.031
0.045
0.046
0.062
0.093
0.125
0.156
0.187
0.187
0.218
0.250
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.250 / (1/4)
.312 / (5/16)
.375 / (3/8)
.375 / (3/8)
.437 / (7/16)
.500 / (1/2)
2
2
2
2
2
2
2
2
2
2
2
2
2
–
–
–
–
–
–
–
–
–
–
–
–
–
0.020
0.031
0.062
0.090
0.093
0.125
0.187
0.250
0.312
0.375
0.375
0.437
0.500
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
–
2.5
2.5
2.5
2.5
2.5
3
3
3
3.5
3.5
4
4
4
Corner
Radius
0.030
0.062
0.093
0.125
Shank
Diameter (h6)
.250 / (1/4)
.250 / (1/4)
.375 / (3/8)
.500 / (1/2)
No. of
Flutes
2
2
2
2
Neck
Diameter
0.115
0.230
0.345
0.460
Cutting
Length
0.125
0.250
0.375
0.500
Neck Length/
Nose Taper
0.375 / 7.5˚
0.750 / 1.125 / 1.500 / -
Overall
Length
2.5
2.5
3.0
3.5
End Mills, Square End Bull Nose,
with Corner Radius, Series EIB
Tool
Ordering No.
EIB-.062-015-EX
EIB-.093-015-EX
EIB-.125-015-EX
EIB-.125-030-EX
EIB-.187-030-EX
EIB-.250-015-EX
EIB-.250-030-EX
EIB-.312-030-EX
EIB-.375-030-EX
EIB-.437-030-EX
EIB-.500-030-EX
End Mill, Ball Nose, Series BI
Tool
Ordering No.
BI.020 EX
BI.031 EX
BI.062 EX
BI.090 EX
BI.093 EX
BI.125 EX
BI.187 EX
BI.250 EX
BI.312 EX
BI.375 EX
BI.375 EXLL
BI.437 EX
BI.500 EX
End Mill, Toroid, Series TOI
Tool
Cutter Diameter
Ordering No.
tol. +0 /–.0004
TOI.125 EX
.125 / (1/8)
TOI.250 EX
.250 / (1/4)
TOI.375 EX
.375 / (3/8)
TOI.500 EX
.500 / 1/2)
All tools backdraft 3 deg.
13
All Tools Available Coated or Uncoated
L1
D2
D1
NEW!
d
L2
New HFI4 (High Feed) Four Flute Solid Carbide
Tool
Ordering
No.
HFI4-0125...
HFI4-0250...
HFI4-0375...
HFI4-0500...
Cutting
Diameter
D1
0.125
0.250
0.375
0.500
Radius
A
Radius
B
0.0100
0.0205
0.0305
0.0406
0.0390
0.0780
0.1170
0.1562
Shank
Diameter
d
0.250
0.250
0.375
0.500
Neck
Diameter
D2
0.115
0.235
0.360
0.485
Length
of Cut
L2
0.0938
0.1500
0.1700
0.1800
Neck
Length
L3
0.650
1.000
1.250
1.500
Overall
Length
L1
3
3
4
4
Step
Over
Ae
0.094
0.187
0.280
0.375
Depth
of Cut
Ap
0.005
0.009
0.014
0.019
Feed
Per Tooth
Fz
.003-.006
.006-.011
.009-.016
.012-.022
3 Flute Endmill, 45°- Aluminum
Tool
Ordering
No.
EISA-0125EISA-0187EISA-0250EISA-0312EISA-0375EISA-0437EISA-0500EISA-0625EISA-0750EISA-1000-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
3 Flute Ballnose, 45°- Aluminum
Shank
Cutting Total
Diameter Length Length
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
0.500
0.625
0.750
0.750
0.875
0.875
1.250
1.250
1.500
1.500
1.5
2
2.5
2.5
2.5
2.5
3
3.5
4
4
2 Flute Long Series Endmills, Ballnose
Tool
Ordering
No.
BI2-0125-LLBI2-0187-LLBI2-0250-LLBI2-0312-LLBI2-0375-LLBI2-0437-LLBI2-0500-LLBI2-0625-LLBI2-0750-LLBI2-1000-LL-
14
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
0.063"
.094"
.125"
.156"
.188"
.219"
.250"
.313"
.375"
.500"
BIA-0125BIA-0187BIA-0250BIA-0312BIA-0375BIA-0437BIA-0500BIA-0625BIA-0750BIA-1000-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
.063"
.094"
.125"
.156"
.188"
.219"
.250"
.313"
.375"
.500"
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
0.500
0.625
0.750
0.750
0.875
0.875
1.250
1.250
1.500
1.500
1.5
2
2.5
2.5
2.5
2.5
3
3.5
4
4
4 Flute Long Series Endmills, Ballnose
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
Tool
Ordering
No.
0.625
1.000
1.000
1.000
1.000
1.000
1.000
2.000
2.000
2.000
2
3
3
3
4
4
4
6
6
6
Tool
Ordering
No.
BI4-0125-LLBI4-0187-LLBI4-0250-LLBI4-0312-LLBI4-0375-LLBI4-0437-LLBI4-0500-LLBI4-0625-LLBI4-0750-LLBI4-1000-LL-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
0.063"
.094"
.125"
.156"
.188"
.219"
.250"
.313"
.375"
.500"
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
0.625
1.000
1.000
1.000
1.000
1.000
1.000
2.000
2.000
2.000
2
3
3
3
4
4
4
6
6
6
4 Flute Variable Fluted Endmills, Square End with 45° Chamfer
Tool
Ordering
No.
EIV4-0125EIV4-0187EIV4-0250EIV4-0312EIV4-0375EIV4-0437EIV4-0500EIV4-0625EIV4-0750EIV4-1000-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
0.500
0.625
0.750
0.750
0.875
0.875
1.250
1.250
1.500
1.500
1.5
2
2.5
2.5
2.5
2.5
3
3.5
4
4
2 Flute Endmills, Square End
1/32"
1/16"
3/32"
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
7/8"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
0.125
0.125
0.125
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
0.875
1.000
0.094
0.250
0.375
0.500
0.625
0.750
0.750
0.875
0.875
1.250
1.250
1.500
1.500
1.500
1.5
1.5
1.5
1.5
2
2.5
2.5
2.5
2.5
3
3.5
4
4
4
7.5 Deg
7.5 Deg
7.5 Deg
-
2 Flute Long Series Endmills, Square End
Tool
Ordering
No.
EIS2-0125-LLEIS2-0187-LLEIS2-0250-LLEIS2-0312-LLEIS2-0375-LLEIS2-0437-LLEIS2-0500-LLEIS2-0625-LLEIS2-0750-LLEIS2-1000-LL-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
Tool
Ordering
No.
BI220-0125BI220-0187BI220-0250BI220-0312BI220-0375BI220-0437BI220-0500-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
.125"
.093"
.125"
.156"
.187"
.218"
.250"
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.0938
0.141
0.188
0.234
0.281
0.328
0.375
1.5
2
2.5
2.5
2.5
2.5
3
4 Flute Endmills, Square End
Tool
Cutter
Corner Shank Cutting Total
Nose
Ordering
Diameter Radius Diameter Length Length Taper
No.
tol. +0 /–.0006 (R1)
(D1)
(L1)
(L2)
Per Side
EIS2-031EIS2-062EIS2-093EIS2-0125EIS2-0187EIS2-0250EIS2-0312EIS2-0375EIS2-0437EIS2-0500EIS2-0625EIS2-0750EIS2-0875EIS2-1000-
220° 2 Flute Endmills Ball End
EIS4-031EIS4-062EIS4-093EIS4-0125EIS4-0187EIS4-0250EIS4-0312EIS4-0375EIS4-0437EIS4-0500EIS4-0625EIS4-0750EIS4-0875EIS4-1000-
1/32"
1/16"
3/32"
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
7/8"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
0.125
0.125
0.125
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
0.875
1.000
0.094
0.250
0.375
0.500
0.625
0.750
0.750
0.875
0.875
1.250
1.250
1.500
1.500
1.500
1.5
1.5
1.5
1.5
2
2.5
2.5
2.5
2.5
3
3.5
4
4
4
7.5 Deg
7.5 Deg
7.5 Deg
-
4 Flute Long Series Endmills, Square End
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
Tool
Cutter
Corner Shank Cutting Total
Nose
Ordering
Diameter Radius Diameter Length Length Taper
No.
tol. +0 /–.0006 (R1)
(D1)
(L1)
(L2)
Per Side
0.625
1.000
1.000
1.000
1.000
1.000
1.000
2.000
2.000
2.000
2
3
3
3
4
4
4
6
6
6
Tool
Ordering
No.
EIS4-0125-LLEIS4-0187-LLEIS4-0250-LLEIS4-0312-LLEIS4-0375-LLEIS4-0437-LLEIS4-0500-LLEIS4-0625-LLEIS4-0750-LLEIS4-1000-LL-
Cutter
Corner
Diameter
Radius
tol. +0 /–.0006 (R1)
1/8"
3/16"
1/4"
5/16"
3/8"
7/16"
1/2"
5/8"
3/4"
1"
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
Shank
Cutting Total
(D1)
(L1)
(L2)
0.125
0.187
0.250
0.312
0.375
0.437
0.500
0.625
0.750
1.000
0.625
1.000
1.000
1.000
1.000
1.000
1.000
2.000
2.000
2.000
2
3
3
3
4
4
4
6
6
6
15
STYLE CY/SFCY
D
D1
.
6
D1
D
L1
L1
L2
L2
Tool
Ordering No.
Size Ø
D
Shank Ø
D1
TAV 06-095-12 NEW
TAV 08-095-12 NEW
CY 10-100-10
CY 10-100-12
TA 10-125-12
TA 10-150-12
SFCY 12-125-12
SFCY 12-150-12
SFTA 12-190-16
SFCY 14-125-16
SFCY 16-160-16
SFTA 16-190-20
SFCY 20-150-20
SFCY 20-190-20
SFTA 20-200-25
SFCY 22-200-25
SFCY 25-150-25
SFCY 25-200-25
SFCY 25-250-25
SFTA 25-250-32
SFTA 25-315-32
SFCY 30/32-190-32
SFCY 30/32-250-32
SFTA 30/32-250-40
SFCY 30/32-300-32
SFTA 30/32-250-42
6
8
10
10
10
10
12
12
12
14
16
16
20
20
20
22
25
25
25
25
25
30 & 32
30 & 32
30 & 32
30 & 32
30 & 32
12
12
10
12
12
12
12
12
16
16
16
20
20
20
25
25
25
25
25
32
32
32
32
40
32
42
D2
L1
L2
5,7
7,5
9
9
9
9
10,8
10,8
10,8
12,6
14,4
14,4
18
18
18
19,8
22,5
22,5
22,5
22,5
22,5
27,2
27,2
27,2
27,2
27,2
30
32
19
25
35
35
36
46
60
36
50
57
50
61
80
50
50
64
64
100
100
57
76
120
57
120
16
D2
STYLE TA/SFTA
D2
95
95
100
100
125
150
125
150
190
125
160
190
150
190
200
200
150
200
250
250
315
190
250
250
300
250
Use with
Insert Style
Insert
Screw
Insert
Torx Key
MS 06N
MS 08N
MS 10
MS 10
MS 10
MS 10
MS 12
MS 12
MS 12
MS 16
MS 16
MS 16
MS 20
MS 20
MS 20
MS 25
MS 25
MS 25
MS 25
MS 25
MS 25
MS 32
MS 32
MS 32
MS 32
MS 32
T7
T7
T15
T15
T15
T15
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T30
T30
T30
T30
T30
NEW!
MBT
VRBS
Precision ground, harder grade,
for semi-finish and finish milling. Excellent
choice for unattended finish milling at small
depth and high speeds and feed rates.
SuperFinisher
Ball Nose Insert
D
L
Part No.
MBT 10
MBT 12
MBT 16
MBT 20
MBT 25
MBT 30
MBT 32
D
10
12
16
20
25
30
32
L
8,65
9,20
11,25
13,15
18,25
22,15
21,95
Small Ball Nose
Insert
D
Unique cutting edge allows performance in all
operations in material below 42 HRc; in semi,
& finishing operations above. Significant
benefits in heat-treated intricate geometries.
Insert geometry allows smoother cutting
motion-diminishing heat build up & tool
deflection, reduces vibration caused by
cutting action.
Ball Nose Insert
D
L
Part No.
MB 10
MB 12
MB 16
MB 20
MB 25
MB 30
MB 32
D
10
12
16
20
25
30
32
Part No.
VRBS-06
VRBS-08
D
L
D
6
8
L
8,1
4,5
cost-effective replacements for solid
carbide ball end mills.
2˚
6
MB
Used for rough- to finish-milling small
radius or detail work, and surface milling
in soft and hard steel, cast iron, aerospace
and non-ferrous alloys, graphite, etc.
Suitable for high speed and hard milling.
For additional tool holders,
see page 20.
8
RB-N
Precision ground, non-chipbreaker. Best
choice for cavity, core and profile milling
of pre-hard and fully hard die/mold steels,
cast steels and cast iron. Strongest cutting
edge design.
Ball Nose Insert
D
L
8,65
9,20
11,25
13,15
18,25
22,15
21,95
L
BS-N
D
10
12
14
16
20
22
25
30
32
L
9,50
9,20
9,45
11,25
13,15
17,45
18,25
22,15
21,95
Sidecutting, non-chipbreaker. Side cutting
insert used in cavity and core profiling, for
blending of fillets on medium and hard
materials.
Ball Nose Insert
D
L
S
Part No.
RB 10 N
RB 12 N
RB 14 N
RB 16 N
RB 20 N
RB 22 N
RB 25 N
RB 30 N
RB 32 N
Part No.
BS 10 N
BS 12 N
BS 16 N
BS 20 N
BS 25 N
BS 30 N
BS 32 N
D
10
12
16
20
25
30
32
L
9,50
8,80
10,70
12,75
17,20
20,00
21,00
S
3,65
2,90
2,85
2,85
4,85
5,10
5,30
17
D2
STYLE CYF
D
D1
D1
L1
L2
TAV 06-095-12 NEW
TAV 08-095-12 NEW
CYF 10-100-10
CY 10-100-10
CY 10-100-12
TA 10-125-12
TA 10-150-12
TAF 10-150-12
CYF 12-125-12
CYF 12-150-12
TAF 12-190-16
CYF 16-160-16
TAF 16-190-20
CYF 20-150-20
CYF 20-200-20
TAF 20-200-25
CYF 25-150-25
CYF 25-200-25
TAF 25-250-32
TAF 25-315-32
CYF 30/32-190-32
CYF 30/32-250-32
TAF 30/32-250-40
L2
Size Ø
D
Shank Ø
D1
6
8
10
10
10
10
10
10
12
12
12
16
16
20
20
20
25
25
25
25
32
32
32
12
12
10
10
12
12
12
12
12
12
16
16
20
20
20
25
25
25
32
32
32
32
40
D2
L1
L2
5,7
7,5
9
9
9
9
9
9
10,8
10,8
10,8
14,4
14,4
18
18
18
22,5
22,5
22,5
22,5
28,6
28,6
28,6
30
32
19
19
25
35
35
35
36
46
60
50
57
50
61
80
50
64
100
100
57
76
120
For your shrink fit and long reach requirements please see pages 9, 10, 21 & 22 for our carbide shank products.
18
.
6
D
L1
Tool
Ordering No.
D2
STYLE TAF
95
95
100
100
100
125
150
150
125
150
190
160
190
150
200
200
150
200
250
315
190
250
250
Use with
Insert Style
Insert
Screw
Insert
Torx Key
MS 06N
MS 08N
MS 10
MS 10
MS 10
MS 10
MS 10
MS 10
MS 12
MS 12
MS 12
MS 16
MS 16
MS 20
MS 20
MS 20
MS 25
MS 25
MS 25
MS 25
MS 32
MS 32
MS 32
T7
T7
T15
T15
T15
T15
T15
T15
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T20
T30
T30
T30
Back Draft and Flat Bottom
inserts are used to best advantage
in applications where small corner
radii are required, for example
finishing of straight and steep side walls,
blending and finishing of small corner radii,
fillets and the like. Toroid Bull Nose Cutters
combine the advantages of popular round insert
toroidal “button cutters” and bull nose end mills
with the proven design of Millstar’s precision, single
strong insert with twin-cutting geometry. The result is
reduced machining time and enhanced accuracy
and surface finish.
The inserts, and particularly the patented toroidal inserts, are designed
to improve 3- and 5-axis milling of dies, molds and similar free-form threedimensional surfaces. The precision ground inserts are held in Millstar’s
proven rock-solid dovetail seat for superior surface finish and machining
accuracy. The insert designs avoid the area of zero cutting speed at the tip
of ball nose inserts for improved tool life.
The toroidal tools in particular have the advantage of cutting at larger
step-over or pitch while leaving no or smaller cusps; the tools also run at
faster cutting speeds and feed rates. The toroidal bull nose design
simplifies 3- and 5-axis programming, works on a variety of materials from
non-ferrous metal, carbon graphite and stainless steels to pre-hard and
fully hard mold and die materials.
z VBD
Used for rough-to finish-milling small radius
or detail work, and surface milling in soft and
hard steel, cast iron, aerospace and nonferrous alloys, aluminum alloys, graphite, etc.
Suitable for high speed and hard milling.
Small Back Draft
Insert
D
Part No.
VBD-06
VBD-08
R
L
1˚
D
L
R
6
8,6
0,4
8
5
0,4
cost-effective replacements for solid
carbide end mills.
For additional tool holders,
see page 18.
TO
Precision ground, large corner radius & back
taper for spiral and pocket milling, milling of
pre-hard and hardened flat surfaces at higher
speeds than tools with smaller corner radii.
Good choice for HS milling of Aluminum.
Toroid Bull Nose
Insert
D
R
L
Part No.
TO 10...
TO 12...
TO 16...
TO 20...
TO 25...
TO 30...
TO 32...
D
10
12
16
20
25
30
32
L
8,65
9,20
11,25
13,15
18,25
22,15
21,95
R
3
3
4
5
6
7,5
8
NEW!
BDS
Unique crossover design between flat
Flat Bottom Insert bottom FB and back draft BD inserts. Allows
straight walls with a larger step down than
BD, but less cutting forces than FB; allows
higher cutting speeds and feeds.
Part No.
D
L
R
R
BDS-1010
3
1
BDS-1212
3
1
L1
BDS-1616
3
1,0 or 1,3
BDS-2020
3
1,0 or 1,6
BDS-2525
3
1,0 or 2,0
BD-N
Precision ground, non-chipbreaker and 7
degree backtaper. Used for milling of
cores, cavities, fillets with straight or very
steep walls of harder material.
Back Draft Insert
D
R
L
Part No.
BD 10 N
BD 12 N
BD 16 N
BD 20 N
BD 25 N
BD 32 N
D
10
12
16
20
25
32
L
8,5
9,95
11,55
13,35
19,95
23,35
R
0,5 / 0,8 / 1,0
0,5 / 1 / 2
0,5 / 1 / 1,3 / 2 / 3
0,5 / 1 / 1,6 / 2 / 3
1/2
1,0 / 2,6
All “BDS” series inserts are non-chip
breaker style**
FB-R
BD-R
Back Draft Insert
D
R
L
chipbreaker and 7 degree backtaper. Used
for milling of cores, cavities, fillets with
straight or very steep walls of softer
material.
Part No.
BD 10 R
BD 12 R
BD 16 R
BD 20 R
BD 25 R
BD 32 R
D
10
12
16
20
25
32
L
R
8,5
0,5 / 0,8 / 1
9,95
0,5 / 1
11,55 0,5 / 1,0 / 1,3
13,35
1,0 / 1,6
19,95
1,0 / 2
23,35
2,6
chipbreaker. Flat bottom insert for shoulder
Flat Bottom Insert milling, fillet finishing and long reach
angular wall finishing of softer materials.
D
R
L
Part No.
FB 06 R
FB 08 R
FB 10 R
FB 12 R
FB 16 R
FB 20 R
FB 25 R
FB 32 R
D
6
8
10
12
16
20
25
32
L
7,0
7,0
8,50
9,15
10,65
12,25
16,35
21,30
R
0,4
0,4
0,8
1
0,5 / 1,3
1,6
2
2,6
19
NEW!
New HF (High Feed) Inserts
Millstar’s new HF insert is designed for High Speed and High Feed
machining. The HF is designed to run at high cutting speeds and feed rates
with shallow depth of cut. The NEW curved geometry
allows the chip to flow up and out of the cut quickly
and smoothly allowing for the use of heavy chip loads.
The geometry of the new HF insert generates cutting
forces upward, toward the spindle, which helps
eliminate vibration and deflection, allowing for very
Tool
Ordering No.
HF-10…
HF-12…
HF-16…
HF-20…
HF-25…
high chip loads. The HF insert is designed to fit into Millstar’s standard flat
holders, style 4 (CYF, TAF and CBCYF) making these holders more versatile
than ever.
The HF insert can be used in the following applications: Roughing, semifinish of all softer materials. Nickel-based alloys and Stainless steel alloys
(XRN coated) to pre-heat treated Tool steels (TLN coated). It can be used
for roughing and semi-finishing of heat-treated materials up to 48 HRc.
Diameter
D
Corner Radius
A
Corner Radius
B
Length
D1
Step Over
Ae
Depth of Cut
Ap
Feed per Tooth
Fz
10
12
16
20
25
0,698
1,000
1,295
1,498
1,905
3,000
4,000
5,000
6,000
7,000
0,266
0,426
0,596
0,775
0,900
7,5
9
12
15
18,75
0,4
0,48
0,64
0,.8
1
0,25-0,5
0,3-0,55
0,4-0,71
0,5-0,89
0,56-1,0
NEW!
New TOBD-NF Back Draft Inserts for
Non-Ferrous Materials
Millstar’s new TOBD-NF insert is specifically designed
for high speed and high feed roughing of Aluminum,
but also has the versatility to be used for fine
finishing as well. This unique cutting edge design
allows the chips to flow freely up the flute allowing higher speeds and
feeds. The TOBD-NF comes in diameters from 1/2 inch (12mm) up to 1 inch
(25mm) and fits into our standard flat type tool holders making the holders
Tool Ordering No.
TOBD-12-NF-NA
TOBD-16-NF-NA
TOBD-20-NF-NA
TOBD-25-NF-NA
Diameter
D
L
R
12,0
16,0
20,0
25,0
9,2
11,25
13,15
18,25
3,0
3,0
3,0
3,0
DISCLAIMER
Today’s metalcutting operations are performed on high horsepower, high spindle speed CNC machines. These operations generate high temperatures, cutting forces and flying
chips. Today’s metalcutting tools can generally hold up under these conditions but they may also chip and fly apart. Adequate protection for workers is a must. All machine
guards and protective equipment should be in place at all times. Grinding carbide, ceramic and other modern materials can create dusts and mists that should be collected by
proper equipment.
Overexposure to dusts and mists can be a hazard to ones health. Dusts and mists can irritate existing skin and or pulmonary conditions. Adequate respiratory, eye protection
and ventilation should be used during grinding and workers should avoid prolonged contact with dusts and mists.
A safe environment must be provided as metalcutting is not just the holder and inserts. The machine, workpiece, clamping method cutting conditions all play a part in today's
metal cutting environment.
Cole Tooling does not assume responsibility and will expressly disclaim liability for loss, damage or expense arising out of or in any way connected with the handling, storage,
use or disposal of these products. Cole Tooling does not warrant it’s products for any particular use or application. All information and recommendations in our catalogs are
only suggestions. All generally accepted safety practices and health regulations should be followed.
20
D2
D
D1
L1
L2
Millstar’s long solid carbide tool shank cutters provide the user with deep milling
solutions for up to ten times diameter in reach. MILLSTAR’s Carbide Tool Shanks
provide many user benefits:
• Increased stiffness – for more aggressive metal removal and long reach, deep milling.
• Large cutting insert choice – the variety of available cutting geometry, tool coatings, and
insert shapes and sizes assures best milling results at lowest machining cost per part.
• Minimized deflection – to machine closer to net shape and tight tolerance.
• Vibration reducing – for smoother surface finish, improved tool life, longer
spindle life.
• Minimized cutter run out – improved milling results in soft to fully hardened
(to 65 HRc) materials.
• Smaller shank to cutter diameter – several sizes have full-length side clearance
to machine straight walls.
• Safe high speed milling – highest tool stiffness and least deflection when
compared with steel and heavy metal tool shanks result in process reliability
and highest safety for operator and machine.
• Shank diameters (h6) – all tool shanks are heat shrink-fit tool
adapter compatible.
Tool
Ordering No.
Size Ø
D
Insert
Style
CBTAV 06-75-12*
6
CBTAV 06-150-12*
6
CBTAV 06-150-12 LT*
6
CBCYV 06-115-12***
6
CBTAV 08-80-12*
8
CBTAV 08-150-12*
8
CBCYV 08-100-12***
8
CBCY 10-150-10
10
CBTA 10-150-12
10
CBSFCY 12-150-12
12
CBCYF 12-150-12
12
CBSFCY 0500-6.0-12**
12,7 (0.5")
CBCYF 0500-6.0-12**
12,7 (0.5")
CBSFCY 16-150-16
16
CBCYF 16-150-16
16
CBSFCY 0750-8.0-18** 19,05/ (0.750")
CBCYF 0750-8.0-18** 19,05 / (0.750")
CBSFCY 20-200-20
20
CBCYF 20-200-20
20
CBSFCY 25-200-25
25
CBCYF 25-200-25
25
CBSFCY 1000-8.0-25**
25,4 (1.0")
CBCYF 1000-8.0-25**
25,4 (1.0")
CBSFCY 30-190-32
30 & 32
*- 6mm and 8mm diameter holders use new insert style
Overall
Length L2
Neck
Length L1/taper
Shank Ø
D1 (h6)
Neck D2
mm
Nose
Taper
Screw/
wrench
75
155
155
115
80
155
100
150
165
165
165
165
165
170
170
225
225
225
225
230
230
230
230
200
35 / 1.5˚
30 / 6˚
70 / 6˚
30 cyl. + 45 / 1.5˚
40 / 1.5˚
30 / 6˚
30 cyl. + 30 / 1.5˚
32
30 / 6˚
52
52
29
29
52
52
38
38
77
77
93
93
47
47
57
12
12
12
12
12
12
12
10
12
12
12
12
12
16
16
18
18
20
20
25
25
25
25
32
5,7
5,7
5,7
5,7
7,5
7,5
7,5
9,0
9,0
10,8
10,8
11,2
11,2
14,4
14,4
17,95
17,95
18,0
18,0
22,5
22,5
22,5
22,5
27,2
3˚ (1.5˚/side)
6˚ (3˚/side)
6˚ (3˚/side)
2˚ (1˚/side)
3˚ (1.5˚/side)
6˚ (3˚/side)
2˚ (1˚/side)
–
6˚ (3˚/side)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
MS 06N / T7
MS 06N / T7
MS 06N / T7
MS 06N / T7
MS 08N / T7
MS 08N / T7
MS 08N / T7
MS 10 / T15
MS 10 / T15
MS 12 / T20
MS 12 / T20
MS 12 / T20
MS 12 / T20
MS 16 / T20
MS 16 / T20
MS 20 / T20
MS 20 / T20
MS 20 / T20
MS 20 / T20
MS 25 / T20
MS 25 / T20
MS 25 / T20
MS 25 / T20
MS 32 / T30
. Part number VRBS and VBD.
**-Tools with smaller shank diameter than cutter diameter for full-length side clearance.
***-Due to the delicate, slender design and the potential for misapplication of this tool, Millstar does not warrant this tool for breakage.
21
Shrink Fit heads are interchangeable between inch and metric. For inch refer to page 10.
NEW!
Shrink Fit System
rigidity and the shrink tolerances offer better accuracy than
screw on type systems. These tools are designed for high speed machining
and hard metal machining and will allow for better tool life as well as better
surface finishes.
Millstar’s Shrink System offers versatility, strength and accuracy. The carbide
shanks and heads are interchangeable between inch and metric versions.
Metric heads fit on inch shanks and inch heads fit on metric shanks. The
12mm and 1/2 inch shanks will accept any head that is the same diameter
or smaller (see chart for connectivity). The carbide shank offers strength and
All diameters are available in short and long length versions.
Shanks for Shrink Fit Heads
Shrink Fit Heads
Tool
Ordering No.
Shank Ø
D1
Length
L1
Length
L2
Tool
Ordering No.
D1
Length
L1
Length
L2
CSS-12-73.6-T1
CSS-12-124.4-T1
CSS-16-104.8-T2
CSS-16-180.9-T2
CSS-20-96.5-T3
CSS-20-172.7-T3
12
12
16
16
20
20
73,6
124,4
104,8
180,8
96,5
172,7
15,24
15,24
16,51
16,51
17,78
17,78
CHTAV-06-T1
CHTAV-08-T1
CHTA-10-T1
CHY-12-T1
CHY-16-T2
CHY-20-T3
CHF-12-T1
CHF-16-T2
CHF-20-T3
11,7
11,7
11,7
11,7
14,0
17,1
11,7
14,0
17,1
43,2
43,2
43,2
43,2
38,2
48,3
43,2
38,2
48,3
22,3
20,9
21,5
21,5
Use With
Insert Style
21,5
L1
L1
L1
L2
T1
D1
CSS-12-73.6-T1 / CSS-12-124.40-T1
CHTAV-06-T1
CHTAV-08-T1
CHY-12-T1
CHF-12-T1
CHTAFV-08-T1
CHTAF-10-T1
6˚
7,97
T1
L2
D1
L2
CHTAV-06-T1
L1
CHTA-10-T1
CHTAFV-06-T1
D1
T1
D1
CHTAV-08-T1
6˚
T1
L2
L1
D1
11,05
L2
CHTA-10-T1
L1
L2
T2
D1
T2
13,97
CSS-16-104.75-T2 / CSS16-180.95-T2
CHY-16-T2 / CHF-16-T2
CHF-16-T2
CHY-16-T2
L1
L1
L2
D1
T3
T3
17,14
CSS-20-96.52-T3 / CSS-20-172.72-T3
22
T1
L1
10,43
CHF-20-T3
CHY-20-T3
6˚
7,67
CHY-20-T3 / CHF-20-T3
CHY-12-T1
CHF-12-T1
High Performance Milling from Heavy Roughing
to Fine Finishing.
Millstar face mills are equally useful on newer high velocity machines and older slower
equipment and will optimize milling performance of all your machine tools. The hardened tool
bodies can be run at aggressive spindle speed and feed rates, when used with Millstar’s
precision ground, strong and thick, round inserts with proven hard, high performance
TLN tool coating.
The tools provide for precision finish results, minimal tool deflection and run-out. Excellent
milling results can be achieved in roughing, semi finishing and fine finishing in Z-level, profiling
or raster cuts, as well as in linear or circular interpolation milling or ramping.
The tools may be used with coolant, but we recommend dry, mist or MQL
(minimum quantity lubrication) milling with strong air blast when high speed or
hard machining steel, particularly in the higher hardness range (> 45HRc / 425
HBN). Please refer to FAQs (frequently asked questions) about milling on our
website www.millstar.com.
Insert Style
FMI-1003
FMI-12T3
FMI-1604
10mm
12mm
16mm
3,18mm
3,97mm
4,77mm
3,88mm
3,9mm
5,2mm
Coating
TLN
TLN
TLN
S3
d1
Diameter Thickness Diameter
d
S
d1
S1
15˚
Tool
Ordering No.
d
S
S2
L2
Arbor Style
Tool
Ordering No.
Cutting
Diameter
D
Neck
Diameter
D1
No.
of
Flutes
Overall
Length
L2
Insert
Required
Insert
Screw
S1
FMA 50/5
FMA 52/5
FMA 63/5
FMA 52/4-16
FMA 63/5-16
50mm
52mm
63mm
52mm
63mm
40mm
40mm
40mm
40mm
40mm
5
5
5
4
5
50mm
50mm
50mm
50mm
50mm
FMI-12T3
FMI-12T3
FMI-12T3
FMI-1604
FMI-1604
FMIS-1
FMIS-1
FMIS-1
FMIS-1
FMIS-1
STYLE 1
S2
L2
L1
FMIS-2
FMIS-2
FMIS-2
FMIS-2
FMIS-2
10.2mm
22.0mm
D1
FMIS-3
FMIS-3
FMIS-3
FMIS-3
FMIS-3
D
STYLE 2
L2
S2
S1
S1
L1
D
D2
D1
Face Clamp Mounting
Screw
Screw
S2
S3
D
D2
D1
Shank Style
Tool
Ordering No.
FM 25/2-180-25
FM 32/3-180-25
FM 32/3-180-32
FM 40/4-180-32
FM 42/4-180-32
FM 32/2-180-32-16
FM 40/3-180-32-16
Cutting Ø
D
Shank Ø
D1
Neck Ø
D2
25mm
32mm
32mm
40mm
42mm
32mm
40mm
25mm
25mm
32mm
32mm
32mm
32mm
32mm
23mm
24mm
29mm
31mm
31mm
31mm
31mm
No. of Neck Length
Flutes
L1
2
3
3
4
4
2
3
100mm
42mm
100mm
42mm
42mm
42mm
42mm
Shank
Style
OAL
L2
1
2
1
2
2
2
2
180mm
180mm
180mm
180mm
180mm
180mm
180mm
Insert
Insert Screw Face Clamp Screw
Required
S1
S2
FMI-12T3
FMI-12T3
FMI-12T3
FMI-12T3
FMI-12T3
FMI-1604
FMI-1604
FMIS-1
FMIS-1
FMIS-1
FMIS-1
FMIS-1
FMIS-1
FMIS-1
FMIS-2
FMIS-2
FMIS-2
FMIS-2
FMIS-2
FMIS-2
FMIS-2
23
• Square nose tools Series EMS / EIS with sharp corner or square nose tools • A new Toroid Series TOI / TOM with large corner radius and slight back
taper is a Millstar innovative addition. It is very useful in I.D. and O.D. ZSeries EIB / EMB with corner radius, all with medium-high helix and strong
level and spiral milling at constant tool pressure, pocket milling, and milling
cutting edges and tool body, work extremely well in materials up to 65HRc
of pre-hard and hardened flat surfaces at higher speeds than tools with
as well as in softer materials.
• Ball nose tools Series BI / BM are designed with two flutes and special nose smaller or sharp corner radii.
geometry for true High Speed and Hard Material milling up to 68 HRc. Ball • Extended Reach ball nose tools Series BMNL and extended reach square
nose tools Series EMR are useful tools specifically designed for long reach
nose tools are the most aggressive tools for these applications. We will be
milling of extrusion dies, deep cavities and cores, deep rib milling and
glad to share our proven approach to improving your machining results.
similar applications. The reduced flute length and neck diameter assure
constant cutting pressure and minimal tool deflection.
End Mills, Square End, Series EMS
Tool
Ordering No.
Cutter Diameter
tol. +0 /–0.01
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
EMS-0.5-EX
EMS-1.0-EX
EMS-1.5-EX
EMS-2.0-EX
EMS-3.0-EX
EMS-4.0-EX
EMS-5.0-EX
EMS-6.0-EX
EMS-8.0-EX
EMS-10.0-EX
EMS-12.0-EX
0.5
1
1.5
2
3
4
5
6
8
10
12
–
–
–
–
–
–
–
–
–
–
–
6
6
6
6
6
6
6
6
8
10
12
3
4
4
4
5
6
6
6
6
6
6
0,5
1
1,5
2,0
3,0
4,0
5
6
8
10
12
1,5
3
4,5
6
9
12
15
18
24
30
36
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
63
63
63
63
75
75
75
75
90
100
100
Cutter Diameter
tol. +0 /–0.01
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
1
1.5
2
3
4
5
6
6
8
10
12
0,2
0,2
0,2
0,3
0,5
0,5
0,5
1
0,5
1
1
6
6
6
6
6
6
6
6
8
10
12
4
4
4
5
6
6
6
6
6
6
6
1
1,5
2
3
4
5
6
6
8
10
12
3
4,5
6
9
12
15
18
18
24
30
36
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
63
63
63
75
75
75
75
75
90
100
100
End Mills, Square End Bull Nose,
with Corner Radius, Series EMB
Tool
Ordering No.
EMB-1.0-0.2-EX
EMB-1.5-0.2-EX
EMB-2.0-0.2-EX
EMB-3.0-0.3-EX
EMB-4.0-0.5-EX
EMB-5.0-0.5-EX
EMB-6.0-0.5-EX
EMB-6.0-1.0-EX
EMB-8.0-0.5-EX
EMB-10.0-1.0-EX
EMB-12.0-1.0-EX
End Mill, Ball Nose, Series BM
Tool
Ordering No.
Cutter Diameter
tol. +0 /–0.01
Ball
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Nose
Taper
Overall
Length
BM 0.5 EX
BM 1.0 EX
BM 1.5 EX
BM 2.0 EX
BM 3.0 EX
BM 4.0 EX
BM 5.0 EX
BM 6.0 EX
BM 8.0 EX
BM 10.0 EX
BM 12.0 EX
BM 16.0 EX
BM 16.0 EX-LL
0,5
1
1,5
2
3
4
5
6
8
10
12
16
16
0,25
0,50
0,75
1,00
1,50
2,00
2,50
3,00
4,00
5,00
6,00
8,00
8,00
6
6
6
6
6
6
6
6
8
10
12
16
16
2
2
2
2
2
2
2
2
2
2
2
2
2
–
–
–
–
–
–
–
–
–
–
–
–
–
0,5
1,0
1,5
2,0
3,0
4,0
5,0
6,0
8,0
10,0
12,0
16,0
16,0
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
7.5˚ / side
–
–
–
–
–
–
63
63
63
63
75
75
75
75
90
100
100
100
150
24
End Mill, Toroid, Series TOM
Tool
Cutter Diameter
Ordering No.
tol. +0 /–0.01
All tools backdraft 3 deg.
TOM 2.0 EX
2
TOM 3.0 EX
3
TOM 4.0 EX
4
TOM 6.0 EX
6
TOM 8.0 EX
8
TOM 10.0 EX
10
TOM 12.0 EX
12
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Diameter
Cutting
Length
Neck Length/
Nose Taper
Overall
Length
0.5
0.5
1.0
1.5
2.0
2.5
3.O
6.0
6.0
6
6
8
10
12
2
2
2
2
2
2
2
1.84
2.76
3.68
5.52
7.37
9.21
11.05
2.0
3.0
4.0
6.0
8.0
10.0
12.0
6 / 7.5˚
9 / 7.5˚
12 / 7.5˚
18 / 24 / 30 / 36 / -
63
63
63
63
75
75
90
Ball End Mill, Extended Reach Tapered Nose,
Series BMNL 1.3 degree neck taper per side
Tool
Ordering No.
Cutter Diameter
tol. +0 /–0.01
Ball
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Dia. / Taper
Cutting
Length
Neck
Length
Overall
Length
2
2
2,5
2,5
3
3
3
3
4
4
4
5
5
6
6
6
8
1
1
1,25
1,25
1,5
1,5
1,5
1,5
2
2
2
2,5
2,5
3
3
3
4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
8
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1,9 / 1,3
1,9 / 1,3
2,4 / 1,3
2,4 / 1,3
2,9 / 1,3
2,9 / 1,3
2,9 / 1,3
2,9 / 1,3
3,9 / 1,3
3,9 / 1,3
3,9 / 1,3
4,9 / 1,3
4,9 / 1,3
5,9 / 5,9 / 5,9 / 7,9 / -
2
2
2,5
2,5
3
3
3
3
4
4
4
5
5
6
6
6
8
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
38,1 / (1,5")
45,70 / (1,8")
50 / (1,95")
31,75 / (1,25")
45,70 / (1,8")
50 / (1,95")
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
38,1 / (1,5")
45,70 / (1,8")
31,75 / (1,25")
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
BM-2.0-EX-1.25NL
BM-2.0-EX-1.80NL
BM-2.5-EX-1.25NL
BM-2.5-EX-1.80NL
BM-3.0-EX-1.25NL
BM-3.0-EX-1.50NL
BM-3.0-EX-1.80NL
BM-3.0-EX-50NL
BM-4.0-EX-1.25NL
BM-4.0-EX-1.80NL
BM-4.0-EX-50NL
BM-5.0-EX-1.25NL
BM-5.0-EX-1.80NL
BM-6.0-EX-1.25NL
BM-6.0-EX-1.50NL
BM-6.0-EX-1.80NL
BM-8.0-EX-1.25NL
End Mill, Square End Bull Nose, with Corner Radius,
Extended Reach Tapered Nose, Series EMR 1.3 degree
neck taper per side
Tool
Ordering No.
Cutter Diameter
tol. +0 /–0.01
EMR-2.0-0.2-EX-1.25NL
EMR-2.0-0.2-EX-1.80NL
EMR-2.0-0.2-EX-50NL
EMR-2.5-0.2-EX-1.25NL
EMR-2.5-0.2-EX-1.80NL
EMR-3.0-0.2-EX-1.25NL
EMR-3.0-0.2-EX-1.80NL
EMR-3.0-0.2-EX-50NL
EMR-4.0-0.2-EX-1.25NL
EMR-4.0-0.2-EX-1.80NL
EMR-4.0-0.2-EX-50NL
EMR-5.0-0.2-EX-1.25NL
EMR-5.0-0.2-EX-1.80NL
EMR-6.0-0.2-EX-1.25NL
EMR-6.0-0.2-EX-1.80NL
EMR-12.0-0.2-EX-1.25NL
EMR-12.0-0.2-EX-1.80NL
2
2
2
2,5
2,5
3
3
3
4
4
4
5
5
6
6
12
12
Corner
Radius
Shank
Diameter (h6)
No. of
Flutes
Neck
Dia. / Taper
Cutting
Length
Neck
Length
Overall
Length
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
0,2
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
12
12
4
4
4
4
4
5
5
5
6
6
6
6
6
6
6
6
6
1,9 / 1,3
1,9 / 1,3
1,9 / 1,3
2,4 / 1,3
2,4 / 1,3
2,9 / 1,3
2,9 / 1,3
2,9 / 1,3
3,9 / 1,3
3,9 / 1,3
3,9 / 1,3
4,9 / 1,3
4,9 / 1,3
5,9 / 5,9 / 11,9 / 11,9 / -
2
2
2
2,5
2,5
3
3
3
4
4
4
5
5
6
6
12
12
31,75 / (1,25")
45,70 / (1,8")
50 / (1,95")
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
45,70 / (1,8")
50 / (1,95")
31,75 / (1,25")
45,70 / (1,8")
50 / (1,95")
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
45,70 / (1,8")
31,75 / (1,25")
45,70 / (1,8")
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
75
Safety Precautions Grinding or other use of this tool may produce hazardous dust and fumes which may endanger health. To avoid adverse health effects, read the material safety data
sheet for this product, as well as for any cutting fluids or material coming into contact with this product – utilize adequate ventilation and appropriate protection. Cutting tools may shatter when broken,
wearing of eye protection is strongly advised in the vicinity of their use.
25
L1
NEW!
D2
D1
d
L2
New HFM4 (High Feed) Four Flute Solid Carbide
Tool
Cutting
Radius
Radius
Shank
Neck
Ordering
Diameter
A
B
Diameter Diameter
No.
D1
d
D2
HFM4-03...
3
0,244
0,940
6
2,74
HFM4-06...
6
0,485
1,875
6
5,61
HFM4-08...
8
0,648
2,500
8
7,62
HFM4-10...
10
0,813
3,124
10
9,60
HFM4-12...
12
0,975
3,750
12
11,61
3 Flute Endmill, 45°- Aluminum - METRIC
Tool
Ordering
No.
EMSA-04EMSA-06EMSA-08EMSA-10EMSA-12EMSA-16EMSA-20-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
14
19
22
25
25
38
38
50
63
63
63
76
88
101
2 Flute Endmills Long Series, Ball End - METRIC
Tool
Ordering
No.
BM2-03-LLBM2-04-LLBM2-06-LLBM2-08-LLBM2-10-LLBM2-12-LLBM2-16-LLBM2-20-LL-
26
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
1,5
2
3
4
5
6
8
10
Overall
Length
L1
76
76
76
100
101
Step
Over
Ae
2,25
4,5
6
7,5
9
Depth
of Cut
Ap
0.12
0.24
0.32
0.40
0.48
Feed
Per Tooth
Fz
,07-,14
,14-,28
,18-,36
,22-,44
,27-,54
16
20
25
25
25
25
50
50
Tool
Ordering
No.
BMA-03BMA-04BMA-06BMA-08BMA-10BMA-12BMA-16BMA-20-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
1,5
2
3
4
5
6
8
10
Shank
Cutting Total
(D1)
(L1)
(L2)
3,000
4,000
6,000
8,000
10,000
12,000
16,000
20,000
12
14
19
22
25
25
38
38
38
50
63
63
63
76
88
101
4 Flute Endmills Long Series, Ball End - METRIC
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
16
20
Neck
Length
L3
16
25
30
33
38
3 Flute Ballnose, 45°- Aluminum - METRIC
Shank
Cutting Total
(D1)
(L1)
(L2)
4,000
6,000
8,000
10,000
12,000
16,000
20,000
Length
of Cut
L2
2,8
3,8
4,0
4,3
4,6
50
76
76
76
101
101
152
152
Tool
Ordering
No.
BM4-03-LLBM4-04-LLBM4-06-LLBM4-08-LLBM4-10-LLBM4-12-LLBM4-16-LLBM4-20-LL
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
1,5
2
3
4
5
6
8
10
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
16
20
16
20
25
25
25
25
50
50
50
76
76
76
101
101
152
152
4 Flute Variable
Fluted Endmills, Square End with 45° Chamfer - METRIC
Tool
Ordering
No.
EMV4-03EMV4-04EMV4-06EMV4-08EMV4-10EMV4-12EMV4-16EMV4-20-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
XX
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
16
20
16
20
25
25
25
25
50
50
38
50
63
63
63
76
88
101
2 Flute Endmills, Square End - METRIC
Tool
Ordering
No.
EMS2-01EMS2-02EMS2-03EMS2-04EMS2-06EMS2-08EMS2-10EMS2-12EMS2-16EMS2-20-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
1*
2*
3
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
4
8
12
14
19
22
25
25
38
38
38
38
38
50
63
63
63
76
88
101
2 Flute Endmills Long Series, Square - METRIC
Tool
Ordering
No.
EMS2-03-LLEMS2-04-LLEMS2-06-LLEMS2-08-LLEMS2-10-LLEMS2-12-LLEMS2-16-LLEMS2-20-LL-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
XX
BM220-03BM220-04BM220-06BM220-08BM220-10BM220-12-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
1,5
2
3
4
5
6
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
2,25
3,00
4,50
6,00
7,50
9,00
38
50
63
63
63
76
16
20
25
25
25
25
50
50
Tool
Ordering
No.
EMS4-03EMS4-04EMS4-06EMS4-08EMS4-10EMS4-12EMS4-16EMS4-20-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
XX
Shank
Cutting Total
(D1)
(L1)
(L2)
3,000
4,000
6,000
8,000
10,000
12,000
16,000
20,000
12
14
19
22
25
25
38
38
38
50
63
63
63
76
88
101
4 Flute Endmills Long Series, Square - METRIC
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
16
20
Tool
Ordering
No.
4 Flute Endmills, Square End - METRIC
Shank
Cutting Total
(D1)
(L1)
(L2)
3,000
3,000
3,000
4,000
6,000
8,000
10,000
12,000
16,000
20,000
220° - 2 Flute Endmills - Ball End - METRIC
50
76
76
76
101
101
152
152
Tool
Ordering
No.
EMS4-03-LLEMS4-04-LLEMS4-06-LLEMS4-08-LLEMS4-10-LLEMS4-12-LLEMS4-16-LLEMS4-20-LL-
Cutter
Corner
Diameter
Radius
tol. +0 /–.015
(R1)
3
4
6
8
10
12
16
20
XX
XX
XX
XX
XX
XX
XX
XX
Shank
Cutting Total
(D1)
(L1)
(L2)
3
4
6
8
10
12
16
20
16
20
25
25
25
25
50
50
50
76
76
76
101
101
152
152
27
FS
Full service roughing and finishing design with precision
ground, sharp cutting edge. Very resistant to edge wear, cratering and
flank wear. Strong cutting edge and excellent chip control on heavy to light
chiploads. With TIN coating, this insert design is the general workhorse and the
economical choice with the widest application range. This insert with TCN or TLN
coating is usually the best choice for the toughest applications in light to
medium-heavy material removal. Refer to additional information under
“Coatings” below and the Millstar application guidelines.
Consult with us on any special needs or applications. We can
tailor grades, geometry and special coatings to optimize your
machining results.
Coatings
NA
Non-coated grade. The lowest cost choice.
May be used at normal speeds, or lower speeds on
older machines, for all purpose milling. May be resharpened
or altered.
ALTiN-EXALON
(TLN)
Titanium aluminum nitride
advanced PVD coating. A special,
improved ALTiN coating
approaching surface hardness of CBN on a tough substrate.
Recommended for tough and hard metal machining applications.
When high cutting temperatures are encountered the coating acts as
a heat barrier, protecting the cutting edge. This allows for aggressive,
high speed and dry milling so often encountered in today’s die and
mold machining. Use on tool, die and higher alloy steels, especially at
hardness over 40 HRc. Also appropriate for all stainless steels (300,
400 and PH series), nickel alloys, titanium, nodular and gray cast iron.
Also useful in machining carbon graphite.
XRN
coating is a multi-layer hybrid coating of
AlTiCrN. This new coating has very good heat
resistance and also a low friction co-efficient. The XRN
coating is designed for use in HSM of un-heat treated softer
materials such as Titanium, Inconel, Stainless Steels and
other gummy materials that require the use of liquid coolant.
TCN
Titanium carbo-nitride PVD multilayer
coating. Higher hardness and toughness than
TIN. Choose on heavy cuts or high feeds and speeds,
preferably with coolant. Excellent crater and wear resistance.
Useful on abrasive and gummy materials (cast iron, brass,
aluminum alloys) and on stainless steels and highly alloyed
materials, including nickel and chrome based alloys.
DMD
Diamond coating. Custom coating for cutting nonferrous, non-metallic and very abrasive materials at
highly elevated speeds. Use on copper, bronze, brass, aluminum-silicon
alloys, carbon graphite, solid and fiber-reinforced plastics, ceramics
and composite materials.
Custom tool coatings for specific applications are available on request.
Feed & Speed Considerations
2. Sidemilling on steep walls
FEED
3. Corner radius milling
FEED
D=Dw
D
ap
FEED
ae
ae
ae
Dw
Choose suitable feed and speed from
recommendations on page 21. These values
must be adjusted (increased), as only part of
the spherical cutter is used and the effective
cutting diameter (Dw) is smaller than the cutter
diameter (D).
28
ROTATION
ROTATION
FEED
FEED
1. Step-over line milling at axial depth of
cut less than half the cutter diameter
Choose suitable feed and speed from
recommendations on page 21. These values do
not need to be adjusted, as the working
diameter (Dw) is equal to the cutter diameter
(D). Climb mill whenever possible.
When milling with small axial width of cut (ae)
feed per tooth values are very high. To avoid tool
breakage, it is important to reduce the tool feed
when reaching the corner of a cavity, as the
engagement and the amount of material removed
increases dramatically.
The recommendations below are suggested parameters for use with Millstar Profile Milling Tools.
Start at a higher speed and lower feed value to avoid initial tool failure. Then adjust speed down and feed rate upward to achieve best metal removal rate
and tool life. Speed and feed rates should be adjusted downward to compensate for poor machine and set-up conditions (loose spindles, machine ways and
feedscrews), long tool reach, smaller insert diameter or full insert engagement. When ball nose inserts are used at a depth of cut less than the full insert
radius, the working diameter (Dw = effective cutting diameter) will be less than the insert diameter. Consult tables A & B on page 25 to calculate speed and
feed based on the working diameter used.
WORK MATERIAL
Carbon, Alloy and Tool & Die
Steels: 4130, P20,H13, D2,
A2, A5, D-M-E No.1,2,3,5
Cast Irons: Grey
Nodular/Ductile
Cast Steel,
low to medium carbon
Stainless Steels:
Austenitic (300 Series)
Martenitic (400 Series)
D-M-E No. 6, 7
Precipitation Hardening(PH)
HARDNESS
HB
Brinell
HRc
Rockwell
50-200
275-320
28-34
200
300
200
300
200
250
300
220
300
350
Nickel Based Alloys
(Inconel, K-Monel, Rene,
Hastelloy, Waspaloy)
Aluminum (<16% Si)
Kirksite (Lead-Tin Alloy)
FEED RATE (inch per tooth)
PREFERRED GEOMETRY
High Speed
Mode
1/4-3/8"
(6-10 mm)
1/2-3/4"
(12-22 mm)
1- 1 1/4"
(25-32 mm)
400-840
360-700
to 1400
to 1200
.001-.003
.001-.003
.002-.006
.002-.006
.003-.008
.003-.008
22
32
440-650
380-430
400-640
360-410
430-720
400-700
250-500
to 1200
to 1100
to 1200
to 1100
to 1400
to 1300
to 1100
.001-.004
.001-.003
.001-.004
.001-.003
.001-.0025
.001-.003
.001-.0025
.002-.008
.002-.006
.002-.008
.002-.006
.002-.0035
.002-.004
.002-.0035
.004-.012
.004-.010
.004-.012
.004-.009
.003-.005
.003-.008
.003-.006
32
38
300-620
300-520
300-440
300-410
to 1200
to 1100
to 1250
to 1000
.0015-.004
.0015-.003
.0015-.003
.0015-.003
.002-.007
.002-.006
.002-.006
.002-.005
.003-.010
.003-.008
.003-.006
.003-.006
.001-.003
.003-.007
.006-.010
.0015-.0035
.0015-.0035
.002-.005
.002-.005
.003-.008
.005-.007
Use chipbreaker
32
32
Brass, Copper, Bronze, etc.
Beryllium Copper
Titanium (Alpha+Beta)
Annealed
Sol. Treated/aged
CUTTING SPEED (SFM)
Conventional
650+
Use non-chipbreaker
geometry, especially on
pre-heat treated materials
Use non-chipbreaker
geometry
Use chipbreaker on softer,
non-chipbreaker geometry on
harder material
Use chipbreaker inserts only
Use TCN or TLN coating
Use chipbreaker inserts
Use TCN or TLN coating
<350
<380
<38
<41
140-375
130-300
100-180
to 800
to 650
to 350
850+
800+
.001-.003
.002-.004
.003-.006
Use TCN or TLN coating and
chipbreaker geometry
.001-.004
.0015-.004
.003-.012
.003-.010
.006-.020
.006-.016
Use NF geometry
Use NF geometry
Wood
1000-2400
2500+
.002-.006
.002-.014
.005-.020
Use NF geometry
Carbon Graphite
1000-1600
2000+
.001-.008
.002-.015
.004-.020
Use N-FS or R-FS
For more aggressive speed & feed recommendations, please visit our website at http://www.millstar.com/application/app_aggr.htm
Calculation Example:
Operation: To mill P20 die steel at 300 BHN with a 1" dia. coated Millstar ball nose insert cutter at a depth of cut of .100"
Step 1 - Find speed range for die steel at 300 HB under column “cutting speed” (360-700 SFM) in above recommendations and choose an above average
starting speed as a starting value = 550 SFM. Choose a feedrate in inches per tooth (fz) at the lower end of corresponding feed range shown
(.003-.008 fz) = .004 fz as starting value.
Step 2 - Determine the actual tool diameter engaged (working dia. Dw). If the depth of cut (DOC) is less than the full insert radius (as in our example), go
to Table A or C (following page) to find working diameter Dw.
Formula: SFM x 3.82 = 550 x 3.82 = 3501 RPM
The working diameter for a 1" insert at .100" DOC is .600" Dw.
Dw
.600
Calculate RPM on basis of Dw and SFM selected:
Step 3 - If the depth of cut is less than the full insert radius (as in our example), the chipload (fz) is reduced. Use the feedrate multipliers on Table B
(following page) to increase feedrate to compensate: Insert dia. 1" at DOC .100" = 1.67. Compensated feed rate: .004" x 1.67 = .00668 fz.
Result - Starting feed and speed values for above operation: 3500 RPM and .0067 fz (rounded off). Feedrate IPM (inches per minute) calculation: 3500 RPM
x .0067 fz x 2 Flutes = 46.9 IPM. All Millstar inserts are 2 Flute effective for balanced cutting and optimized feed.
Note: Follow all safety precautions. Do not run tools at high speeds unless special high velocity guarding and safety precautions are followed, and
toolholder with tool and insert are properly balanced. Contact factory for further information.
Safety Note: Tools can chip or fracture in use, always wear safety glasses, use machine guards and wear protective clothing.
29
Table A: Working Diameter for Ball Nose Tools
Insert Diameter
“D”
.250
Depth
of cut
.020
.135
.050
.200
.075
.229
.100
.245
.125
.250
.156
.188
.250
.312
.375
.500
.625
.312
.375
.500
.625
.750
Dw WORKING DIAMETER (inch)
(actual effective cutting diameter)
.153
.169
.196
.220
.242
.229
.255
.300
.339
.374
.267
.300
.357
.406
.450
.292
.332
.400
.458
.510
.306
.345
.433
.500
.559
.312
.370
.464
.541
.609
.375
.484
.573
.650
.500
.612
.707
.625
.739
.750
Table A: Working Diameter for Ball Nose Tools
1.00
1.25
.280
.436
.527
.600
.661
.726
.781
.866
.927
.968
1.00
.314
.490
.594
.678
.750
.827
.893
1.00
1.082
1.146
1.225
1.250
Table B: Feedrate Multiplier for Ball Nose Tools
Insert Diameter
“D”
.250
Depth
of cut
.020
1.85
.050
1.25
.075
1.09
.100
1.02
.125
1.00
.156
.188
.250
.312
.375
.500
.625
.312
.375
.500
.625
.750
FEEDRATE MULTIPLIER FACTORS
for Working Diameters Dw on Table A
2.04
2.22
2.55
2.84
3.00
1.36
1.47
1.67
1.84
2.00
1.17
1.25
1.40
1.54
1.67
1.07
1.13
1.25
1.37
1.47
1.02
1.06
1.15
1.25
1.34
1.00
1.01
1.08
1.16
1.23
1.00
1.03
1.09
1.15
1.00
1.02
1.06
1.00
1.02
1.00
.500
.625
.750
Dw WORKING DIAMETER (inch)
(actual cutting diameter of toroid inserts)
.385
.465
.544
.450
.541
.630
.479
.579
.675
.495
.604
.707
.500
.618
.720
.625
.745
.750
1.00
1.25
3.75
2.29
1.90
1.67
1.51
1.38
1.28
1.15
1.08
1.03
1.00
4.00
2.55
2.10
1.84
1.66
1.51
1.40
1.25
1.15
1.09
1.02
1.00
1.00
1.25
.696
.800
.867
.900
.933
.964
.984
1.000
.845
.964
1.031
1.083
1.125
1.166
1.198
1.237
1.250
30
32
7.7
10.8
15.0
18.0
20.4
22.4
24.0
26.6
28.3
29.6
30.0
7.9
11.1
15.5
18.7
21.2
23.2
25.0
27.7
29.7
31.2
32.0
Insert Diameter
"D"
6
Depth
of cut
0.5
1.8
1.0
1.2
2.0
1.0
3.0
.0
4.0
5.0
6.0
8.0
10.0
12.5
16.0
8
2.0
1.5
1.1
1.0
1.0
10
12
16
20
25
FEEDRATE MULTIPLIER FACTORS
for Working Diameters Dw, Table A
2.2
2.5
2.8
3.2
3.5
1.6
1.8
2.0
2.2
2.5
1.2
1.3
1.5
1.6
1.8
1.1
1.1
1.2
1.4
1.5
1.0
1.1
1.2
1.2
1.3
1.0
1.0
1.1
1.1
1.2
1.0
1.0
1.1
1.2
1.0
1.0
1.1
1.0
1.0
1.0
30
32
3.8
2.6
1.9
1.6
1.4
1.3
1.2
1.1
1.1
1.0
1.0
4.0
2.8
2.0
1.7
1.5
1.4
1.3
1.2
1.1
1.0
1.0
.500
.625
.750
1.00
FEEDRATE MULTIPLIER FACTORS (inch)
for Toroid Working Diameters Dw on Table C
1.85
2.04
2.22
2.55
1.25
1.36
1.47
1.67
1.09
1.17
1.25
1.40
1.02
1.07
1.13
1.25
1
1.02
1.06
1.15
1
1.01
1.08
1
1.03
1
Insert Diameter
"D"
Depth
of cut
0.5
1.0
2.0
3.0
4.0
5.0
6.0
8.0
10
12
16
20
25
Dw WORKING DIAMETER (Metric)
(actual cutting diameter of toroid inserts)
7.3
9.3
11.9
14.3
17.8
8.5
10.5
13.3
16.0
19.6
9.7
11.7
14.9
18.0
22.0
10.0 12.0
15.8
19.2
23.4
16.0
19.8
24.3
20.0
24.9
25.0
30
32
20.4
22.5
25.2
27.0
28.3
29.2
29.7
30.0
21.6
23.8
26.6
28.5
29.9
30.8
31.5
32.0
30
32
2.6
1.9
1.4
1.2
1.2
1.1
1.0
1.0
2.8
2.0
1.5
1.2
1.2
1.1
1.0
1.0
Table D: Feedrate Multiplier for Toroid Tools
1.25
2.84
1.84
1.54
1.37
1.25
1.16
1.09
1.02
1
For speed and feed calculations on Toroid Bull Nose Tools, use the information on
previous page. For working diameter and feed rate multiplier values, use Table C & D
below when milling with Toroid tools.
30
3.9
5.3
6.9
7.7
8.0
10
12
16
20
25
Dw WORKING DIAMETER (Metric)
(actual effective cutting diameter)
4.4
4.8
5.6
6.2
7.0
6.0
6.6
7.7
8.7
9.8
8.0
8.9
10.6
12.0
13.6
9.2
10.4
12.5
14.3
16.2
9.8
11.3
13.9
16.0
18.3
10.0 11.8
14.8
17.3
20.0
12.0
15.5
18.3
21.4
16.0
19.6
23.3
20.0
24.5
25.0
Table C: Working Diameter for Toroid Tools
Table D: Feedrate Multiplier for Toroid Tools
Insert Diameter
“D”
.375
Depth
of cut
.020
1.85
.050
1.25
.075
1.09
.100
1.02
.125
1
.156
.188
.250
.312
8
Table B: Feedrate Multiplier for Ball Nose Tools
Table C: Working Diameter for Toroid Tools
Insert Diameter
“D”
.375
Depth
of cut
.020
.260
.050
.325
.075
.354
.100
.370
.125
.375
.156
.188
.250
.312
Insert Diameter
"D"
6
Depth
of cut
0.5
3.3
1.0
4.5
2.0
5.7
3.0
6.0
4.0
5.0
6.0
8.0
10.0
12.5
16.0
Insert Diameter
"D"
Depth
of cut
0.5
1.0
2.0
3.0
4.0
5.0
6.0
8.0
10
12
16
20
25
FEEDRATE MULTIPLIER FACTORS (Metric)
for Toroid Working Diameters Dw, Table C
1.8
1.8
2.0
2.2
2.5
1.2
1.2
1.5
1.6
1.8
1.0
1.0
1.1
1.2
1.3
1.0
1.0
1.0
1.1
1.1
1.0
1.0
1.1
1.0
1.0
1.0
For speed and feed calculations on Toroid Bull Nose Tools, use the information on
previous page. For working diameter and feed rate multiplier values, use Table C & D
below when milling with Toroid tools.
Nomenclature
D =
Dw
z
Vc
n
Vf
f
cutter/insert diameter
= effective cutter diameter
= number of teeth
= cutting speed
= number of revolutions
per minute
= feed rate, or table feed
= feed per revolution
fz
Fzcor
CF
x
•
ap
= feed per tooth
= feed/tooth, chip thinning
corrected
= centerline feed, helical
interpolation
= multiplier symbol (inch)
= multiplier symbol (metric)
= axial depth of cut
ae
R
SFM
RPM
IPM
Cutting Speed
π x D x RPM
To find the SFM
SFM =
= 0.262 x D x RPM
12
of a cutter:
Example:
To find the SFM of
.262 x D x RPM = 0.262 x 0.75 x 6000 = 1179 SFM
a 3/4" Ø cutter
rotating at 6000 RPM:
n • • Dw
Metric Formula:
vc =
= m / minute
1000
width of cut, step-over
insert radius
surface feet per minute
revolutions per minute
inch per minute, feed rate
3.14159...circle,
circumference:dia. ratio
Rth,ae = theoretical surface roughness
in step-over direction
Rth,fz = theoretical surface roughness
in feed direction
B = bore dia., helical interpolation
IC = inscribed circle (2 x R)
Q = metal removal rate
Spindle Speed
To find the RPM
of a cutter:
Example
To find the RPM of a 1/2"
Ø cutter rotating at 800 SFM:
12 x SFM
π x D
RPM =
RPM =
Metric Formula:
=
3.82 x 800
.500
3.82 x SFM
D
= 6112 RPM
vc • 1000
π • Dw
n =
= min-1
Feed Rate or Table Feed
Feed Per Tooth
To find the feed
per tooth of a cutter:
Example
To find the feed per tooth of a two flute
cutter rotating at 10000 RPM with
a table travel of 240 inches per minute:
FZ =
240
= 0.012 FZ
2 x 10 000
2
√R
2
- (R - ap )
2
- (0.5 - 0.040)2 = 0.392"
D
ap
R
Metric Formula:
use same formula in mm.
V1
Surface Roughness, Step-Over
Dw
√
√
√
To find the effective cutter
Dw = 2 x R2 - (R - ap )2 + (D - 2R)
Ø of a Toroid bull nose tool:
Example
Dw = 2 x .18752 - (.1875 - .1)2 + (.75 - (2 x .1875)) = .707
To find the
effective cutter diameter
engaged of a 3/4" Ø Toroid
ap
D
bull nose tool cutting at
R
0.100" depth of cut:
Dw
√
Vf
Metric Formula: use same formula in mm.
D2 - ae2
D
R th,ae =
To find the surface
2
4
roughness in step-over direction:
Example
To find the theoretical roughness
.75
.75 2 - .032
of a 3/4" Ø ball nose tool in
R th,ae =
= 0.0003"
2
4
step-over direction of the cut
(peak-to-valley or cusp height),
with a 0.030 step-over value:
v f = n • f z • z = mm / minute
= mm / tooth
Effective Cutting Diameter, Toroid
Dw = 2 x
√0.5
To find the feed (table feed)
IPM = RPM x f z x z
in inches per minute:
Example
To find the feed per tooth of a
IPM = 5000 x 0.006 x 2 = 60 IPM
two flute cutter rotating at
5000 RPM with a feed per tooth of 0.006:
Metric Formula:
vf
n • z
Effective Cutting Diameter, Ball Nose
Dw = 2 x
IPM
z x RPM
FZ =
f =
Metric Formula:
To find the effective
cutter Ø of a ball nose tool:
Example
To find the effective cutter
diameter engaged of a 1.0" Ø
ball nose tool cutting at
0.040" depth of cut:
=
=
=
=
=
=
Surface Roughness, Feed Direction
To find the surface
roughness in feed direction:
Example
To find the theoretical roughness
of a 3/4" Ø ball nose tool
in feed direction of the
R th,fz =
cut (peak-to-valley or
cusp height), with a 0.005
feed per tooth value:
R th,fz
.75
2
√ .75
=
2
D
2
√ D 4- f
2
z
2
- .0052
= 0.000008"
4
31
WORLD HEADQUARTERS
30200 Ryan Road
Warren, MI 48092 U.S.A.
Tel: (586) 573-9450
Toll Free: 877-MILLSTAR (877-645-5782)
Fax: (586) 573-9451
Email: info@millstar.com
Website: www.millstar.com
AUTHORIZED DISTRIBUTOR
MILL-5000-106
Printed and Manufactured in U.S.A.
© Copyright 2007 Cole Tooling Systems

Millstar 2007 Interactive Catalog

Transcription

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